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Lincoln Electric 7H User's Manual

1. Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age cables de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas forte ment toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 jamais enrouler le c ble lectrode autour de n importe quel
2. Worn nozzle or cable liner i Partially flashed or melted contact tip Ji Replace contact tip j Incorrect idle roll pressure j Set idle roll pressure per section on Idle Roll Pressure Setting Improper liner tip or guide tube k Install proper equipment 2 Variable or hunting arc Wrong size worn and or melted fa Replace tip remove any spatter on end of contact tip tip Worn work cable or poor work b Inspect Repair or replace as necessary connection Loose electrode connections c Be sure electrode lead is tight in wire feeder contact block gun nozzle and gun tip tight Wrong polarity d Check connection at output studs for polari ly required by welding process Problem with serial communica e Make sure control cable connections are tions in control cable tight Check for consistent WFS Make sure parameters on Power Source display such as WFS match those on wire feeder display if not see Problem 14 otherwise try chang ing Synergic 7 control board If problem per sists refer to Power Source trouble shooting information 44 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed SYNERGIC 7 amp 7H LINCOLN E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout t
3. Adjusting either encoder knob automati cally transfers display and indicator light to the function being adjusted Volts Trim or Wire Feed Speed Top Light indicates Voltmeter Function has been selected and arc voltage in volts will be displayed along with electrode polarity when the trigger has been pressed When the trigger is not pressed this will serve as a preset voltage trim function and the preset voltage trim will be displayed The top light blinks when arc voltage is being displayed and stays lit when preset volt age trim is displayed The last welding voltage displayed before the weld is stopped will continue to be displayed for 5 seconds after welding to permit operator monitoring SYNERGIC 7 amp 7H LINCOLN P B 2 The preset voltage trim may be adjusted using the Volts Trim encoder knob The syn ergic preset voltage trim level may be adjust ed within the range synergically set by the power source for the process and weld Feed Speed being used The power source auto matically determines whether preset volt age or percent trim will be displayed Preset voltage is indicated by one digit only to the right of the decimal point while per cent trim always displays two digits to the right of the decimal point Middle Light Indicates Run In Speed Function has been selected and the Run In speed setting is being displayed in IPM or m m see section for English or Metric dis play As shippe
4. Includes a 2 51mm O D Spindle with adjustable brake and two locations for mounting the spindle to allow for the mounting of 50 60lb 10 30 Ib 13 14lb and 8 O D coils with proper spindle adapters See OPERATION section Capable of being mount ed on the top of a suitable power source or surface without the need for any other mounting kit Optional features available for this stand include e K1555 1 insulated lift bale e K1556 1 caster kit e K1557 1 swivel platform 60 LB 27 2 KG COIL ADAPTER K1504 1 Permits 50 60 Ib 22 7 27 2 Kg coils to be mounted to a 2 51mm spindle K1551 1 INSULATED LIFT BALE Provides a bolt on lift bale with an electrically insulated lift hook K1556 1 CASTER KIT Comes with 4 light duty 2 O D casters which mount in place of the rubber feet on the wire stand Use in light duty applications where portability is required Can be used in combi nation with the K1557 1 swivel platform K1557 1 SWIVEL PLATFORM Allows for the mounting of the wire feeder reel stand assembly on top of a suitable power source if the need for the wire feeder reel stand assembly to swivel is desired Also has mounting holes in the base feet for mounting to any surface that it can be fastened to Comes with a rotating tool tray to hold gun tips guide tubes drive rolls etc Will work in combination with the K1556 1 caster kit WIRE REEL ASSEMBLY K303 50 60 Ib 22 7 27 2 kg Wire reel mounting
5. of J5 on PC board with trigger closed If voltage is 224 VDC then replace motor assembly If lt 24 VDC replace Control PC board see Procedure for replacing PC boards If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed SYNERGIC 7 amp 7H LINCOLN B E 4 TROUBLESHOOTING E 4 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION 7 No control of wire feed a Problem with serial communications fa If WFS and preset Volts Trim parame ters on wire feeder display do not match those on power source display see Problem 14 b Defective wire feed motor tach or b Measure voltage across pin 2 of J3 control PC Board and pin 3 of J8 on PC board with motor running If voltage is 1 5 3 5V then replace control PC board see Procedure for Replacing PC Boards If not then replace tachometer 8 No wire feed solenoid or arc volt a Faulty gun or gun trigger switch Remove gun Check continuity age LED display indicated between trigger pins with trigger Synergic 7 has input power closed If no continuity repair or replace gun b Defective control PC board or Remove gun Check voltage across gun connector trigger sockets on gun connector If voltage gt 11
6. 16 1 6mm Cored or Solid KS655 1 16 045 052 1 2 1 4mm Solid KS655 052S 045 052 1 2 1 4mm Cored KS655 052C 035 0 9 1 0mm Cored KS655 035C 035 0 9 1 0mm Solid KS655 035S 030 0 8mm Solid KS655 030S 023 0 6mm Solid KS655 025S Aluminum Wire Sizes 1 16 1 6mm KS656 1 16A KS647 1 16A KS656 3 64A KS647 3 64A KS647 040A KS656 035A 3 64 1 2mm 040 1 0mm 035 0 9mm Drive rolls for only cored electrode sizes are stencilled with a C suffix to the wire sizes Drive rolls for only solid electrode sizes are stencilled with an S suffix to the wire sizes Drive rolls for aluminum wire sizes are stencilled with an A suffix to the wire sizes Not for Synergic 7H model For use with Binzel European guns Installation instructions are included with these kits INPUT CABLE ASSEMBLIES K649 Used with Power Wave 450 500 Consists of an 8 conductor control cable with a 14 pin control cable plug and a 4 0 107mm electrode cable with Twist Mate connector It is rated at 500 amps 60 duty cycle and is available in lengths of 7 ft 2 m 17 ft 5 m 25 ft 7 6 m 33 ft 10 m and 50 ft 15 m K675 Used with Power Wave 450 500 Similar to K649 but includes a gas hose with a 5 8 18 male fitting for the Synergic 7 inlet It is rated at 500 amps 60 duty cycle and is available in lengths of 7 ft 2 m 25 ft 7 6 m and 50 ft 15 m K641 Used wit
7. A 9 Optional Features Installation A 10 OGM RE Section B Safety PFECAUTIONS u uuu ua and B 1 RIDE B 1 Keypad Setup and Operation iii B 1 Procedure Selector Switch AA B 4 Dual Procedure Remote Control K1449 1 B 4 Wire R elILGAdIng k uu na a iii B 5 Idle Roll Pr ssu r Setting es deeg eege tii B 9 Gas Guard Regulator Setting sse B 9 Makingia Wold BE B 10 Wire R el GHa gifg S B 10 Wire Feed Overload Protection aaa B 10 Grounding Lead Protector su B 11 Explanation of Prompting and Error Messages B 11 ACCESSOFTIES NK A Section C Optional FSatiles EE C 1 Maintenance s Section D Safety PRECAUTIONS uuu lle lid daa D 1 Routine Maintenance sise D 1 Periodic Maintenance rise resume einen teens tn tentes D 1 Troubleshooting assassanin a Section E Safety EE E 1 Neel ee ne RE E 2 Procedure for Replacing PC Boards E 12 DIELIcU rg Section F WINN W F 1 Input CONNECTION E IE F 2 DIMENSION dn LEE F 3 vi B INSTALLATION SS TECHNICAL SPECIFICATIONS SYNERGIC 7 AND 7H WIRE FEEDER 4 ROLL Model SYNERGIC 7 SYNERGIC 7H Wire Speed Range IPM 50 770 80 1200 M M 1 25 19 5 2 00 30 5 Wire Size Capabilities Solid Electrodes 025 1 16 025 045 0 6 1 6mm 0 6 1 2mm Cored Electrodes
8. Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 standards 4 b Use suitable clothing made from durable flame resistant 5 b material to protect your skin and that of your helpers from the arc rays Protect other n
9. Power Wave 450 Similar to K648 but includes a gas hose with a 5 8 18 male fitting for the Synergic 7 inlet It is rated at 500 amps 60 duty cycle and is available in lengths of 7 ft 2 m 25 ft 7 6 m and 50 ft 15 m K640 Used with Power Wave 450 and Synergic 7 7H with water quick connection Similar to K648 but includes a gas hose with a 5 8 18 male fitting for the Synergic 7 inlet and water hoses with quick connect male fittings to connect between the water cooler and Synergic 7 water connections It is rated at 500 amps 60 duty cycle and is available in lengths of 7 ft 2 m 25 ft 7 6 m and 50 ft 15 m K651 Used with Power Wave 350 Consists of an 8 con ductor control cable with a 14 pin plug and 2 0 67 mm2 electrode cable with Twist Mate connector lt is rated at 350 amps 60 duty cycle and is available in lengths of 7 ft 2 m 17 ft 5 m 33 ft 10 m and 50 ft 15 m K677 7 Used with Power Wave 350 Similar to K651 but includes a gas hose with a 5 8 18 male fitting for the Synergic 7 inlet It is rated at 350 amps 60 duty cycle and is available in 7 ft 2 m length K650 Used with Power Wave 350 and Synergic 7 7H with water quick connection Similar to K651 but includes a gas hose with a 5 8 18 male fitting for the Synergic 7 inlet and water hoses with quick connect male fittings to connect between the water cooler and the Synergic 7 water connec tions It is rated at 350 amps 60 duty
10. VDC then gun is defective If voltage is lt 11 VDC then check the voltage across pin 2 and pin 8 of connector J1 on control PC board If the voltage is still x 11 VDC then replace control PC board See Procedure for replacing PC boards Otherwise either the gun connector or wiring harness is faulty 44 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed SYNERGIC 7 amp 7H LINCOLN E 5 TROUBLESHOOTING E 5 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION 9 Wire feed motor runs and solenoidja Power source is defective a If arc voltage is present when wire feeder is turns on but no arc voltage pre connected to the other input receptacle 1 or sent 2 of power source then power source is defective Otherwise select a stick procedure on power source connect a known good input cable see step b to wire feeder 1 receptacle of power source and jumper across sockets C and D of 8 socket input cable plug If no arc voltage is present refer to display on power Source then power source is defective b Input cable is defective b Disconnect input cable from power source and wire feeder Check continuity between socket C of 8 socket pl
11. and 045 1 2mm solid electrodes The electrode sizes that can be fed with each roll and guide tube are stencilled on each part Check the kit for proper components Steel Wire Sizes 4 Roll 068 3 32 1 7 2 4mm Cored KS655 3 32 4 16 1 6mm Cored or Solid KS655 1 16 045 052 1 2 1 4mm Solid KS655 052S 045 052 1 2 1 4mm Cored KS655 052C 035 0 9 1 0mm Cored KS655 035C 035 0 9 1 0mm Solid KS655 035S 030 0 8mm Solid KS655 030S 023 0 6mm Solid KS655 025S Aluminum Wire Sizes KS656 1 16A KS647 1 16A KS656 3 64A KS647 3 64A KS647 040A KS656 035A 1 16 1 6mm 3 64 1 2mm 040 1 0mm 035 0 9mm Drive rolls for only cored electrode sizes are stencilled with a C suffix to the wire sizes Drive rolls for only solid electrode sizes are stencilled with an S suffix to the wire sizes Drive rolls for aluminum wire sizes are stencilled with an A suffix to the wire sizes Not for Synergic 7H model For use with Binzel European guns Installation instructions are included with these kits Also requires K489 2 Fast Mate Adapter INSTALLATION A 6 PROCEDURE TO INSTALL DRIVE ROLL AND GUIDE TUBES A WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring When inching with gun trigger electrode and drive mechanism are hot to work and ground and
12. being displayed and is adjustable with the Wire Feed Speed rotating encoder control If selected this light will blink while welding indicating that the display has been select ed to display welding amps and continues for 5 seconds after the weld is stopped memory ammeter Timer Crater Select key enables operator to choose spot or gas timers or crater speed as indicated by the appro priate light Pressing the key causes lights to sequence left to right top to bottom starting from the current indi cated selection Any parameter not available in the mode selected is skipped over Top Left Light indicates preflow time is being displayed in seconds Top Right Light indicates postflow time is being dis played in seconds Middle Light indicates Crater Feed Speed is being dis played This display will only occur if 4 step mode with crater fill is selected Bottom Light indicates spot on time is being displayed in seconds Increase arrow key increases the setting of the para meter selected to be displayed Arrow keys do not function for Wire Feed Speed or Volts Trim settings which are adjusted using the rotating encoder knobs Decrease arrow key decreases the setting of the para meter selected to be displayed Arrow keys do not function for Wire Feed Speed or Volts Trim settings which are adjusted using the rotating encoder knobs A 5 INSTALLATION INSTALLATION OF THE SYNERGIC 7 COMPONENTS Safety Pre
13. cycle and is avail able in lengths of 7 ft 2 m 17 ft 5 m 33 ft 10 m and 50 ft 15 m K642 Control Cable Only Consists of an 8 conductor control cable with a 14 pin control cable plug without elec trode cable and is available in lengths of 7 ft 2 m 17 ft 5 m 25 ft 7 6 m 33 ft 10 m and 50 ft 15 m K643 Control Cable Extension Consists of an 8 con ductor control cable with 14 pin connectors on each end for extending the control cable between the power source and the control cables Available in lengths of 17 ft 5 m 25 ft 8 m 33 ft 10 m and 50 ft 15 m With input power disconnected from the power source install the input cable per connection diagram S21041 in the rear of this manual and follow exactly the instructions on the diagram or perform the follow ing 1 Connect the end of the control cable with the 14 pin cable plug to the mating receptacle on the power source 2 Connect the electrode lead of that same cable end to the power source output terminal of the desired polarity 3 Route the other end of the electrode cable through the large oval hole in the rear panel of the Synergic 7 case Connect to the brass block on the side of the gearbox using the bolt provided SYNERGIC 7 amp 7H LINCOLN A 10 4 Connect the remaining end of the control cable with the 8 socket cable plug to the mating recepta cle on the Synergic 7 a Install the input cable under
14. for control of overrun When used with Readi Reels a Readi Reel adapter is required K435 Permits 14 Ib 6 kg Innershield coils to be mounted on 2 51mm O D spindles For use with optional K162H adapter K468 Permits 8 203mm O D spools to be mount ed on 2 51mm O D spindles For use with optional K162H adapter GUN AND CABLE ASSEMBLIES K126 Innershield gun and cable assemblies are rated at 350 amps 60 duty cycle Maximum wire size for Synergic 7 models is 5 64 2 0 mm Not recom mended for Synergic 7H models Consult sales spec ifications for appropriate models K115 Innershield gun and cable assemblies are rated at 450 amps 60 duty cycle Maximum wire size for Synergic 7 models is 5 64 2 0 mm Not recom mended for Synergic 7H models Consult sales spec ifications for appropriate models K470 Magnum 300 GMAW gun and cable assemblies are rated 300 amps 60 duty cycle Consult sales specifications for appropriate models K471 Magnum 400 GMAW gun and cable assemblies are rated 400 amps 60 duty cycle Consult sales specifications for appropriate models K497 Magnum 200 GMAW gun and cable assemblies are rated 200 amps 60 duty cycle Consult sales specifications for appropriate models K541 Magnum 400 Short Neck GMAW gun and cable assemblies are rated 400 amps 60 duty cycle Consult sales specifications for appropriate models K598 Magnum 550 GMAW gun and cable assemblies are rated 5
15. for K1524 1 A swivel plat form can be added to the K1524 1 Universal Wire Reel Stand The K1557 1 includes a pivot top plate and a base assembly The pivot top plate mounts to the underside of the base of the wire stand assembly using four screws The swivel base mounts to the power source lift bale with hardware provided or it can be mounted to a surface of choice with four customer provided bolts Installation instructions are provided with the kit SYNERGIC 7 amp 7H LINCOLN B 1 OPERATION B 1 OPERATING INSTRUCTIONS Safety Precautions A WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring When inching with gun trigger electrode and drive mechanism are hot to work and ground and could remain energized several seconds after the gun trigger is released Turn OFF input power at welding power source before installation or changing drive roll and or guide tubes Welding power source must be connected to system ground per the National Electrical Code or any applicable local codes Only qualified personnel should perform this installation Observe all additional Safety Guidelines detailed throughout this manual Duty Cycle The Synergic 7 models are rated at 60 duty cycle for a maximum current of 600 amps Based on a 10 minute time period 6 minutes on and 4 minutes off KEYPAD SETUP AND OPERATION Power Down Save Power
16. for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b SAFETY WELDING SPARKS can lt gt cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Pi
17. it almost touches the roll Tighten in place 10 Install the remaining guide tube in the front hole Be certain that the proper plastic insert is used Fine wire chisel point tube must have largest radius next to drive roll Tighten in place 11 Re latch both quick release levers 12 To start new electrode straighten the first 6 150mm and cut off the first 1 25 mm Insert free end through the incoming tube Press gun trigger and push wire into the drive roll TO SET IDLE ROLL PRESSURE see Idle Roll Pressure Setting Gun and Cable Assemblies GMAW Guns An expanding line of Magnum gun and cable assem blies are available to allow welding with solid and cored electrodes using the GMAW process See the appropriate Magnum literature for descriptions of the 200 to 550 ampere air cooled gun and cables that are available Gun cable lengths range from 10 ft 3 0 m to 25 ft 7 6 m and feed electrode sizes 025 0 6 mm to 5 64 2 0 mm The entire line of Magnum Fast Mate gun and cable assemblies can also be used by installing a K489 1 Fast Mate adapter kit Innershield Guns K126 and K115 gun and cable assemblies are available to allow welding with Innershield elec trodes Gun cable lengths range from 10 ft 3 0 m to 15 ft 4 5 m The 350 ampere K126 with Synergic 7 will feed electrode sizes 062 1 6 mm to 5 64 2 0 mm The 450 ampere K115 with Synergic 7 will feed 5 64 2 0 mm electrode Three smoke extrac
18. it unwinds from the bottom as the reel rotates 3 Tighten the spinner nut against the reel cover as much as possible by hand using the reel cover spokes for leverage DO NOT hammer on the spinner nut arms 4 Cut and remove only the tie wire holding the free end of the coil Hook the free end around the rim of the reel cover and wrap it around to secure Cut and remove the retaining tie wires 44 CAUTION Always be sure the free end of the coil is securely held while the tie wires are being cut and until the wire is feeding through the drive rolls Failure to do this will result in backlash of the coil which may tangle the wire A tangled coil will not feed so it must either be untangled or discarded 5 Be sure the coil is engaged with the spindle brake pin and the Release Bar and Retaining Collar pops up and that the collar retainers fully engage the retaining groove on the spindle FIGURE B 3 K1504 1 COIL REEL SPINNER NUT SPRING LOADED ARM Feeding Electrode 1 Turn the reel until the free end of the electrode is accessible While tightly holding the electrode cut off the bent end 2 Straighten the first 6 150mm and cut off the first 1 25mm Insert the free end through the incoming guide tube Press the Cold Inch key or the gun trigger and push the electrode into the drive roll Feed the electrode through the gun If the electrode is not properly straightened it may not feed or ma
19. lator per See Installation section Shielding Gas Connections INSTALLATION A 11 K1524 1 Universal Wire Reel Stand The assembly includes a reel stand a 2 51 mm O D spindle with adjustable brake rubber mounting feet and a cable clamp for fastening the input cable It is easily mount ed to the wire feed unit by three bolts The wire feed er reel stand assembly fits on top of the power source and is correctly positioned by using a hole in the base that accommodates the power source lift bale The 2 51mm O D spindle can be set on one of two mount ing locations on the stand depending on what coil of wire and spindle adapter is being used The upper hole mounts 50 60 Ib coils the lower hole mounts 10 30 Ib 13 14 Ib and 8 O D coils Installation instruc tions are included with the kit K1555 1 Insulated Lift Bale Kit for K1524 1 A lift bale can be added to the K1524 1 Universal Wire Reel Stand The K1555 1 provides electrical insula tion between the wire stand assembly and the lift hook It is easily mounted to the wire stand with three bolts and a threaded plate Installation instructions are included with the kit K1556 1 Caster Kit for K1524 1 A light duty caster kit can be added to the K1524 1 Universal Wire Reel Stand The K1556 1 includes 4 2 O D light duty casters that mount in place of the rubber feet on the wire stand base Installation instructions are included with the kit K1557 1 Swivel Platform
20. of the Gas Guard regulator See Below Gas Guard Regulator The Gas Guard Regulator is an optional accessory K659 1 on these models Install the 5 8 18 male outlet of the regulator to the 5 8 18 female gas inlet on the back panel of the Synergic 7 Secure fitting with flow adjuster key at top Attach gas supply to 5 8 18 female inlet of regulator per instructions in the Gas Connections Section SYNERGIC 7 amp 7H LINCOLN A 9 INSTALLATION A 9 ELECTRICAL INSTALLATION A WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring When inching with gun trigger electrode and drive mechanism are hot to work and ground and could remain energized several seconds after the gun trigger is released Turn OFF input power at welding power source before installation or changing drive roll and or guide tubes Welding power source must be connected to system ground per the National Electrical Code or any applicable local codes Only qualified personnel should perform this installation Observe all additional Safety Guidelines detailed throughout this manual Input Cable Synergic 7 Wire Feeder to Power Wave Synergic Type Power Sources NOTE CSAnril certification of the Synergic 7 models is with input cable assemblies identified by carton date codes 010161 or above These assemblies have grounding lead continuity between the 14 pin plug
21. on timer times out even through the trigger is still closed SYNERGIC 7 amp 7H LINCOLN P B 2 OPERATION Display Control Keys The function select timer crater select arrow keys and rotational encoders all effect the display Pressing the function select key will cause a function to be displayed Pressing the timer crater select key will cause a timer or crater feed speed to be displayed Whichever is pressed last is the one that will be displayed since they cannot be displayed simultaneously Only one function or timer indicator light can be on at one time and therefore it always indicates what is being displayed The arrow keys allow you to adjust the Run in speed timer or crater speed being dis played The encoder knobs allow rotational adjustment of weld wire feed speed and Arc Volts Trim Note If an indicator light is skipped that parameter may not be enabled Refer to section covering that parameter Function Select key enables oper E V VOLTS TRIM ator to choose which function will e olo RUNN e ojo vrs be displayed as indicated by the appropriate light Pressing the key causes lights to sequence top to bottom starting from the current indicated position If a timer or crater speed is being displayed when the Function Select key is pressed then the indicator light of the last function selected before the timer crater key was chosen will come on and become the starting point for the sequencing
22. stand Assembly includes a framework to which is attached the 50 60 Ib 22 7 27 2 kg wire reel a mounting spindle a dust shield a lift bail and a cable clamp for fastening the input cable assembly The reel mounting spindle is the pull knob type with a built in brake The brake pad is adjustable for proper brak ing at low or high wire feed speeds In extremely dusty and dirty locations a wire reel dust shield door kit can be added to this unit This door kit which includes a hinged door and sliding bottom seal makes the housing completely enclosed Order part number M11514 K376 Same as K303 above but without dust shield A dust shield that covers the wire reel and protects the wire from falling dirt and dust is available for this unit Order part number 814543 This unit will also accept the M11514 door kit see K303 above but only if already equipped with optional dust shield S14543 K377 Small mounting stand for Readi Reel coils or 10 30 Ib 4 5 14 kg spools with 2 51 mm I D This assembly includes a small frame to which is attached a 2 51 mm O D wire reel spindle and a K363P Readi Reel adapter for using the Lincoln Readi Reel Electrode Coils Without the adapter the unit is capable of handling spools with a 2 51 mm I D a 12 305 mm maximum O D and a 4 101 mm width K378 Small mounting stand for 13 14 Ib 6 kg Innershield coils This assembly includes the same smaller frame as used in the K3
23. the gun trigger is released Turn OFF input power at welding power source before installation or changing drive roll and or guide tubes Welding power source must be connected to system ground per the National Electrical Code or any applicable local codes Only qualified personnel should perform this installation Observe all additional Safety Guidelines detailed throughout this manual CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed SYNERGIC 7 amp 7H LINCOLN E 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION 1 Rough wire feeding or wire not a Gun cable kinked and or twisted Ja Inspect gun cable and replace if feeding but drive rolls turning necessary b Wire jammed in gun and cable b Remove wire from gun and cable feed in new wire Note any obstructions in gun and cable Replace gun and cable if neces sary Incorrect position of drive rolls with c See Wire Feed Drive Roll and grooves Guide Tubs Kits section for proper installation of drive roll Drive rolls loose d Remove clean install and tighten Gun cable dirty e Clean cable or replace liner Worn drive roll Electrode rusty and or dirty
24. then the wire feeder and the power source after Preflow time See Timer Crater Section 2 Releasing the trigger turns off the wire feeder and power source and then the solenoid valve after Postflow time Middle Light Indicates 4 Step Lock Trigger Mode These models have selectable 4 step with crater fill or as shipped 4 step with current interlock See 4 step trigger mode selection for method of switching The 4 step modes function as follows 1 Trigger closure energizes the power source and wire feeder after the pre flow time 2 Trigger release enables 4 step lock leaving the feeder and power source as in step 1 a 4 step with current interlock will only lock if weld current is flowing Breaking weld arc stops wire feed and power source output b 4 step with crater fill will lock without welding 3 Closing the trigger a second time continues welding a 4 step with current interlock contin ues welding without changing the settings from step 2 b 4 step with crater fill continues weld ing but changes to the crater set tings 4 Releasing the trigger turns off wire feeder and power source and then gas solenoid after postflow time Bottom Light Indicates Spot Weld Mode Trigger closure energizes the solenoid valve then wire feeder and the power source The spot on timer starts when current flows The wire feeder and power source then sole noid valve are all turned off when the spot
25. tion keys and indicator lights are concealed behind a hinged drop door cover Encoder Controls Rotating encoders provide con tinuous knob control for setting both Wire Feed Speed and Volts Trim procedures Procedure Switch Permits selection of A or B pro cedures as set by the procedure controls and memo ry pair selected at the Power Wave power source Setting switch to center Gun Switch position allows selection of A or B procedures with the optional Dual Procedure Switch Keypad Consists of 7 membrane keys with tactile feel embossed domes All keys are generously spaced to provide easy selection even if wearing welding gloves INSTALLATION A 3 2 Step or 4 Step Trigger Modes Unit operates only when trigger is pressed in 2 Step mode normal oper ation 4 Step Trigger Mode eliminates the need to hold the gun trigger closed while welding Both mod els have user selectable 4 step with crater fill or as shipped 4 step with current interlock Gas Preflow and Postflow Timers Allows setting of shielding gas preflow time 0 2 5 seconds before welding arc starts and gas postflow time 0 9 9 seconds after welding arc stops Crater Fill Allows setting of crater fill WFS when 4 step with crater fill trigger mode is selected indepen dent of weld cold feed and run in speeds Selectable Burnback Time Provides front panel selection of 6 Burnback times This feature provides selectable Burnback t
26. 0 duty cycle Consult sales specifications for appropriate models K478 Magnum 300 FM GMAW gun and cable assemblies are rated for 300 amps 60 duty cycle Consult sales specifications for appropriate models K479 Magnum 400 FM GMAW gun and cable assemblies are rated for 400 amps 60 duty cycle Consult sales specifications for appropriate models K556 GMAW process Magnum 400XA X TRAC TOR gun and cable assemblies are rated at 400 amps 6096 duty cycle Consult sales specifications for appropriate models SYNERGIC 7 amp 7H LINCOLN C 4 ACCESSORIES K566 GMAW process Magnum 250XA X TRAC TOR gun and cable assemblies are rated 250 amps 60 duty cycle Consult sales specifications for appropriate models K179 type vacuum unit not recommended for use with Synergic 7 MISC OPTIONS K590 4 Water Connection Kit Includes water sup ply quick connectors already attached to mounting insulators and internal connection hoses for easy installation on the front and rear panels of the Synergic 7 case Also includes water cooled gun tube fittings and self sealing outlet and inlet quick connec tors for mounting to the front of the Synergic 7 case K659 1 Gas Guard Regulator Adjustable flow regu lator with removable adjustor key for CO2 and Argon blend gases Mounts onto wire drive gas inlet and reduces gas waste and arc start blow by reducing surge caused by excess pressure in supply hose K144
27. 045 3 32 045 1 2 2 4mm 1 2mm Input Power 40 42 V 10 50 60 Hz 4 0 Amps Temperature Rating Operating Storage 20 C to 40 C 40 C to 40 C The following is for both the Synergic 7 and Synergic 7H models Size amp Weight Without Wire Stand With K377 Wire Stand 269 mm 10 60 550 mm 21 66 295mm 11 60 295mm 11 60 282mm 11 11 432mm 17 00 Total Weight 12 9 kg 28 5 lbs 17 5 kg 38 5 lbs Less Electrode SYNERGIC 7 amp 7H LINCOLN A 2 GENERAL DESCRIPTION The Synergic 7 is a semiautomatic constant speed wire feeder designed specifically for use with the Invertec Power Wave type power sources A serial communication link is supplied through the control cable of the Synergic 7 enabling information to be shared between the power source and wire feeder The Synergic 7 comes factory equipped with a gas solenoid valve with gas fittings and standard Lincoln gun connector These models includes a 3 1 2 digit LED display with rotating knob encoder controls for setting the wire feed speed and voltage and a dual pro cedure selector switch A tactile feel keypad provides selection of operating mode function selection timer and crater fill selection and parameter adjustment Two keys provide Cold Feed and Gas Purge functions and connector receptacles are provided for an optional dual procedure remote control and dual procedure switch The unit has 3 operating mo
28. 1300 31009 u31VM 40 SQv31H399ldl 8 N XO8HV39 03348 HOH 401 HAdWNNF V N ass xov 18 8 SNIQOO 40109 QV31 28613 HM STO8NAS 1v9IH103T3 qavog O d IOHLNOO e ry E OR VSS Ce n vato ee coa lt o 4 eo 1 EGG lego 196 008 n 296 cn 2 GION3T1OS Sv9 O 318V9 3004193134 LAdNI ana A18N3SSV GIOHOL d H C a TE 19 P HOVL Z SISYANAS INVH9VIQG 9NIUIA L 4 3llHM M ein pl 038 y Sr For 1 g Oif quvOS O d 40 3018 IN3NOdWOO 30N3N03S SNIB3SINPN Nid luo 89U819 21 104 SI urejBeip SIUL LON Gei bas 340H0 4 u er 8d il 4 HO193NNOO 10 3QIS GV31 NON FONINOSS NIHIANNN ALIAVO HOLOANNOO AAA s Z er Ba En Pod quvO8 O d 40 3018 LNINOdWOO XX 30N3N038 NIHJANWNN ALIAVO y 319V1d3938 318V9 1NdNI Tor M349S SNIGNNOYS 3Svo Lx i s s o lt lt e i i i i i i i i i i i i i j 1 CH M cross 390144 Qd anoo ATIVOLL3NOS VN HOLIMS 0338 iuo Z anis ri ONIONNOYD O n n asvo D I 03d oil SYNERGIC 7 amp 7H LINCOLN E DIAGRAMS F 2 INPUT CONNECTION DIAGRAM F 2 b LvOLZS 300819313 d001 WNOO Tvld3S d001 WNOO Tvld3S OV Act ev MIIA HV34H Ofrid 318V9 13 908 8 ONY WOCH OM Id JIBVO Nid T ANY LINOUIO Geo MAA NO OS Nao MIIA INOH4 370V1d3038 XO8 1391008 51 noua OL Qv31 ONIONTIOHE NOILONN 4 9n N D 318Vv9 d30334 HUIM OL 394N0S
29. 1514 K377 Small Mounting Stand for Readi Reel Coils or 10 44 Pound 4 5 20 kg Spools with 2 1 D This assembly includes a small frame to which is attached a wire reel spindle similar to the K162 Spindle The unit is supplied with the K363 Readi Reel Adapter for using the Lincoln Readi Reel Electrode Coils Without the adapter the unit is capable of handling spools with a 2 51mm I D a 12 30mm maximum O D and a 4 101mm width For spools with an 8 200mm O D a K468 spindle adapter is available The spindle has an adjustable braking system See Installation section Attaching the Wire Reel Stand for mounting to wire feed unit K378 Small Mounting Stand for 13 14 Pound Innershield Coils This assembly includes the same smaller frame as used in the K377 and a fully enclosed canister system for de reeling of the 14 pound 6 kg coil This system has a fixed brake for this coil See Installation section Attaching the Wire Reel Stand for mounting to wire feed unit K659 1 Gas Guard Regulator Adjustable flow regu lator with removable adjustor key for CO2 and Argon blend gases Mounts onto feeder inlet and reduces gas waste and arc start blow by reducing surge caused by excess pressure in supply hose Install the 5 8 18 male outlet of the regulator to the 5 8 18 female gas inlet on the back panel of the Synergic 7 Secure fitting with flow adjuster key at top Attach gas supply to 5 8 18 female inlet of regu
30. 50 amps 6096 duty cycle Consult sales specifications for appropriate models K206 Innershield Linconditioner gun and cable assemblies are rated 350 amps 60 duty cycle Maximum size for Synergic 7 models is 5 64 2 0 mm Not recommended for Synergic 7H models Consult sales specifications for appropriate models K289e Innershield Linconditioner gun and cable assemblies are rated 500 amps 60 duty cycle Maximum size for Synergic 7 models is 5 64 2 0 mm Not recommended for Synergic 7H models Consult sales specifications for appropriate models K309e Innershield Linconditioner gun and cable assemblies are rated 250 amps 60 duty cycle Maximum size for Synergic 7 models is 5 64 2 0 mm Not recommended for Synergic 7H models Consult sales specifications for appropriate models K179 type vacuum unit not recommended for use with Synergic 7 The following Lincoln gun and cable assemblies are equipped with a Fast Mate connector They can be used with these Synergic 7 models by installing a K489 1 Fast Mate adapter kit K684 Magnum Water Cooled FM water cooled GMAW gun and cable assemblies are rated 450 amps 100 duty cycle COz Consult sales specifi cations for appropriate models K498 Magnum 200 FM GMAW gun and cable assemblies are rated for 200 amps 60 duty cycle Consult sales specifications for appropriate models K534 Magnum 250L FM GMAW gun and cable assemblies are rated for 250 amps 3
31. 77 and a fully enclosed canister system for de reeling of the 14 Ib 6 kg coil This system has a fixed brake for this coil K445 50 60 Ib 22 7 27 2 kg Readi Reel mounting stand This assembly includes framework to which is attached a 2 51 mm O D spindle with adjustable brake and 50 60 Ib 22 7 27 2 kg K438 Readi Reel adapter Includes a lift bail and cable clamp for fas tening the input cable assembly Does not include a dust shield A dust shield that covers the wire reel and protects the wire from falling dirt and dust is avail able for this unit Order part number S14543 This unit will also accept the M11514 door kit see K303 above but only if already equipped with optional dust shield S14543 SYNERGIC 7 amp 7H LINCOLN B C 3 ACCESSORIES C3 READI REEL ADAPTERS K363P Adapts Lincoln Readi Reel coils of electrode 30 Ib 14 kg and 22 Ib 10 kg to a 2 51mm spindle Durable molded plastic one piece construction Designed for easy loading adapter remains on spin dle for quick changeover used with K162H K438 Adapts Lincoln Readi Reel coils of electrode 50 60 Ib 22 7 27 2 kg to a 2 51mm spindle used with K162H SPINDLE ADAPTERS K162H Spindle for mounting Readi Reels and 2 51mm LD spools with 60 Ib 27 2 kg capacity The shaft for the standard wire coils is removed from the mounting frame work and the K162H is installed in its place Includes an easily adjustable friction brake
32. 9 1 Dual Procedure Remote Control Includes a remote control box with a 16ft 5m length control cable with 4 pin plug for the mating receptacle on the bottom of the Synergic 7 control box The remote control box contains 2 rotating knob encoders one controls arc voltage and the other controls weld wire feed speed and a procedure selector switch which function the same as comparable controls on the front panel which are disabled when the remote is con nected K683 1 Dual Procedure Switch Kit includes gun switch and mountings for Lincoln Innershield and Magnum guns with 15 ft 4 5 m control cable and 3 pin plug K163 Undercarriage For all Synergic 7 wire reel stand combinations Includes mounting frame front casters 10 254 mm O D rear wheels and handle Use when portability is required K178 1 Swivel Platform For all Synergic 7 wire reel stand combinations For mounting wire feeder wire reel stand assembly on top of suitable Lincoln Idealarc power sources Recommended input cable length is 7 ft 2 m when using the K178 1 on the Invertec power sources SYNERGIC 7 amp 7H LINCOLN B D 1 MAINTENANCE D 1 MAINTENANCE Safety Precautions A WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring When inching with gun trigger electrode and drive mechanism are hot to work and ground and could remain energized several seconds after
33. AREY cuts 13 ai tha Jada Y e Aale Cual Al dl Aaaa LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR f 5 881 BHO x bp IEEE k lt HA ETISRIUCEFEUS EL TRHOKRERE GEO F ux 8B ET AERE SRL EE g SI Es Rr TE fit D Ei A REE ARIAS MET R D A ERE o Al Soll AIXAM SALAD HAY zeit TAS PSP HHCH Saal veel al dl illai 2 y Llana J al ply all od Gail call lla ag ls Ca L LINCOLN e World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
34. Drive Features Wire Drive Unit Incorporates low voltage permanent magnet motor and highly efficient two reduction spur gearbox which operates in any position The non fluid lubricant won t leak Quick Release Wire Feed System Provides a completely tool less means for releasing and opening the idle roll pressure arm precisely adjusting the idle roll pressure and changing the incoming and outgoing guide tubes and drive rolls Drive Rolls and Guide Tubes Provide long life positive feeding and precise alignment of electrode Minimizes birdnest or mill thru of wire if properly set Ordered separately Tachometer Feedback Provides proper wire feed acceleration and speed accuracy independent of fluc tuations in line voltage and wire loading for reliable arc starting and weld consistency Run in Speed Setting Allows the arc striking speed Run in to be adjusted independently of the weld feed speed for starting optimization Cold Feed Speed Provides cold feed speed adjustment independent of weld run in and crater speeds Selectable Acceleration Provides front panel selec tion of 5 acceleration rates This feature in combina tion with Run in Speed provides the ability to easily optimize starting on any process or procedure Solid State Dynamic Braking Quickly stops wire feed motor to minimize wire overrun during weld termina tion Solid state design requires no maintenance SYNERGIC 7 amp 7H L
35. Dual Procedure Switch to select A or B along with the remote both the front panel and remote Procedure selector switches must be set to Gun Switch center position SYNERGIC 7 amp 7H LINCOLN P B 5 OPERATION B 5 WIRE LOADING Loading a 22 to 30 Lb 10 to 14 kg Readi Reel Package Using the Molded Plastic K363 P Readi Reel Adapter The Spindle should be located in the LOWER mounting hole of the K1524 1 Universal Stand if used 1 Depress the Release Bar on the Retaining Collar and remove it from the spindle NOTE Earlier spindles used a threaded collar See Figure B 1a or B 1b 2 Place the Adapter on the spindle 3 Re install the Retaining Collar Make sure that the Release Bar pops up and that the collar retainers fully engage the retaining groove on the spindle 4 Rotate the spindle and adapter so the retaining spring is at the 12 o clock position 5 Position the Readi Reel so that it will rotate in a direction when feeding so as to be de reeled from the bottom of the coil FIGURE B 1a Threaded Locking Collar 2 IN O D SPINDLE ADAPTER GROOVES READI REEL INSIDE CAGE WIRES THREADED LOCKING COLLAR 6 Set one of the Readi Reel inside cage wires on the slot in the retaining spring tab 7 Lower the Readi Reel to depress the retaining spring and align the other inside cage wires with the grooves in the molded adapter 8 Slide the cage all the way onto the adapter until the retaini
36. INCOLN A 3 Crater Fill Provides crater feed speed adjustment in 4 step trigger mode independent of weld cold inch or run in speeds Solid State Overload Protection No circuit breaker to reset Front panel display indicates time remaining before automatic reset Gas Solenoid Valve Complete with inlet fittings for easy installation of gas is standard on Synergic 7 models Also available as an option K659 1 a Gas Guard regulator for flow surge suppression English Metric Speed Display Provides front panel selection of speed display in units of IPM or M M 4 Roll Drive Both models employ 4 Roll Drive with 2 driven rolls providing optimal feeding force for prob lem feeding situations with low wire deformation for improved feeding of soft wires Control Features Microcomputer Based Control Provides precise setting and display of all parameters and precision timing functions Optimizes wire drive control for crisp acceleration and smooth response with precise repeatability Allows synergic control of various weld ing processes by communicating information over a serial link to the compatible power source Display and Indicator Lights Wide temperature range long life 3 1 2 digit 7 segment LED display with 56 14 2mm character height permits easy viewing even from long gun cable distances Individual red indicator lights are high intensity LED s for viewing at almost any angle Mode and Timer func
37. RETURN TO MAIN MENU Se IM557 Synergic and H August 2005 For use with machine Code Numbers 10250 and 10251 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thought ful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful NRTL C OPERATOR S MANUAL E ISO 9001 Lo ANSI RAB EJ 27 N CAS Desig ra D LINCOLN lo Copyright 2005 Lincoln Global Inc e World s Leader in Welding and Cutting Products e Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com ABS Quality Eval to ISO 9001 Re CERTIFICATE NUMBER 30273 SAFETY A WARNING CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasolin
38. Synergic 7 input cable assemblies con nect the water hoses to the coolant inlet and outlet on the back of the Synergic 7 Connect the other ends of these hoses to the appropriate ports on the water cooling units JS In the event the water line fittings on your water cooled gun are incompatible with the female quick connects on the front of the Synergic 7 male quick connects are provided for installation on 3 16 5 mm LD hose Customer to provide appropriate clamps The feeder connectors self seal when disconnected GMAW Shielding Gas A WARNING CYLINDER may explode if damaged x Keep cylinder upright and chained to E support p Keep cylinder away from areas where it may be damaged Never lift welder with cylinder attached Never allow welding electrode to touch cylinder Keep cylinder away from welding or other live elec trical circuits BUILDUP OF SHIELDING GAS may harm health or kill e Shut off shielding gas supply when not in use SEE AMERICAN NATIONAL STANDARD Z 49 1 SAFETY IN WELDING AND CUTTING PUBLISHED BY THE AMERICAN WELDING SOCIETY Customer must provide a cylinder of shielding gas a pressure regulator a flow control valve and a hose from the flow valve to the gas inlet fitting of the Synergic 7 Wire Feed Unit Connect a supply hose from the gas cylinder flow valve outlet to the 5 8 18 female inert gas fitting on the back panel of the Synergic 7 or if used on the inlet
39. TION German WARNUNG ATENCAO Japanese ER BIR Korean Do nottouch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja a e Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension e Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e N o toque partes el tricas e elec trodos com a pele ou roupa molha da e Isole se da peca e terra o REPOR RABE 7 amp nfdcsn zucct OMLMPT APSSAPREBS NTUSHILT FSU e E GUB MIU AER AER GH Oa CRM ER ecu Saiss Xe sd EE 472 a Sal OHAR e sis HIE Weal HAR A W ou uil el all Quali Y O Y ll ai ay Ast gl o as lala AA ll Jaul DIS dan ule Y Jio wae Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo e Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda dos e RAPIOENDOMTO REIR MMIC U THEW EKA e 18 9 2 Vi S BET freA eis Ad d s Jo UN al gh pa 832 Na AIX ole Wear eye ear and body protection e Prot jase los ojos los o dos y el cuer
40. Y3MOd 49 3 NVE9VIO DNISIM 31VIHdOHddY 339 INAWdINOA HNOA NI LN3S3Ud 38 LON AVN HO AVN HOV3 NV AINO AT85Y T 8V2 LONI 39N343338 403 031811 38V SNOILONNA 4 DIDYANAS HOM OL 318v9 NI 319V9 300810313 Q3193NNOO LON 3UV 31SI1 LON SNid ON AlldV Od 43d04d OL 39Hf0S H3MOd NO E 3dnq3908d dfi 138 ANY 394N0S YAMOd LV S318VO AYOM ANY 3308103 H 3843138 4401 HIMOd NN ALld 10d 39NVHO OL 3ALLISOd 300819313 SMOHS NV4DVIO ON NOILVONMddV 40 31949 ALNG SYNLNA ANY 3430334 34IM 1N384N9 401 Q3Zl 38 LSAW 318V9 O9NIGT3M V N 34 2ION3NAS Td JAVMYIMOd NIOSNIT ie TI NV9 MOOHS AUIYORW SU 99 1188 3419373 10 esn je sul pjnous suosied payljenb ju e Jepeoj M ay Bunoeuuoo e10J8q 891N0S JAMOJ Bulpjem ey uo uoyiMs amod ay 440 UN s ONINEVM Y SYNERGIC 7 8 7H LINCOLN E DIAGRAMS F 3 DIMENSION PRINT F 3 20102 S 26 81 0 INIdd NOISNAWIG A18 SV XO4 1081NOO Y 34140 38IM 1104 YW9Z NT 60 8 Got 7 J3ONVH31OL m S39v1d GNVLS 1338 SHIM OL XO8 10HINO9 DIN HOJ SMIYOS GH X3H 91 8 LLLI SYNERGIC 7 amp 7H LINCOLN E NOTES SYNERGIC 7 amp 7H LINCOLN NOTES SYNERGIC 7 amp 7H LINCOLN NOTES SYNERGIC 7 amp 7H LINCOLN NOTES SYNERGIC 7 amp 7H LINCOLN WARNING Spanish AVISO DE PRECAUCION French ATTEN
41. actory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you Step 3 RECOMMENDED COURSE OF ACTION locate and repair possible machine malfunctions This column provides a course of action for the Simply follow the three step procedure listed below Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP If you do not understand or are unable to perform the TOMS This column describes possible symptoms Recommended Course of Action safely contact your that the machine may exhibit Find the listing that local Lincoln Authorized Field Service Facility best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom WARNING e ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring When inching with gun trigger electrode and drive mechanism are hot to work and ground and could remain energized several seconds after
42. al damage A safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication P l Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 i SAFETY i PR CAUTIONS DE S RET 5 Toujours porter des lunettes de s curit dans la zone de Pour votre propre protection lire et observer toutes les instruc tions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suivantes S r
43. apter is required For 8 O D 200 mm spools a K468 Spindle Adapter is available INSTALLATION A 10 K163 Undercarriage Requires K303 K376 K377 or K378 The undercarriage includes casters wheels a handle and related hardware Casters are mounted at the front and the wheels to the rear of the platform The handle is bolted to the front of the platform so the Synergic 7 can be tilted back and wheeled like a two wheel truck Instruction sheet M13424 for assembly installing the K303 K376 K377 or K378 wire stand is provided with the undercarriage K683 1 Dual Procedure Switch Dual Procedure Switch mounts to gun with appropriate bracket provid ed per the installation instructions included with the kit 3 pin switch cord plug connects to 3 pin remote receptacle on the front panel of the Synergic 7 Wire Feed Unit K1449 1 Dual Procedure Remote Control Provides remote rotating knob encoder control of Wire Feed Speed and Volts Trim along with a dual procedure selector switch which disables comparable front panel controls when the remote control is connected The 4 pin plug of the remote control connects to the mating receptacle on the bottom of the Synergic 7 Control box K590 4 Water Connection Kit Install per the instruc tions shipped with the kit K648 K649 K651 or K642 Input Cable Assembly See Electrical Installation section for instructions K675 K676 or K677 Input Cable Assembly Gas See Electrica
44. as Purge and Up Arrow key again returns WFS display to wire speed while welding The toggle switch on the front panel provides selection of Procedure A or Procedure B as set with the front panel knob controls Rotating the knob encoder changes only the procedure selected by this switch Also this switch selects the A or B memory pair select ed at the Power Wave power source NOTE The dual procedure overlay must be present on the Power Wave power source for the Procedure Selector switch to function If this overlay is not used only Procedure A will be selected no matter what position the Procedure switch is in Setting the toggle switch to the center Gun Switch position permits the Procedure A or Procedure B to be selected by the optional K683 1 Dual Procedure Switch The K1449 1 Dual Procedure Remote Control can be used with this panel Procedure Switch in any position OPERATION B 4 Dual Procedure Remote Control K1449 1 When this option is connected to the feeder control receptacle the front panel knob controls are disabled and procedure control is transferred to the knob encoder controls of the remote which function in the exact same manner NOTE The dual procedure overlay must be pre sent on the Power Wave power source for the Procedure Selector switch to function If this overlay is not used only Procedure A will be selected no matter what position the Procedure switch is in If using the optional K683 1
45. at the same time displaying acceleration setting per above then pressing the function key a second time while holding gas purge pressed dis plays the burnback time selection Default is b0 which is zero delay Selecting b1 through b5 increases delay from 10 m sec to 50 m sec in 10 m sec increments To exit this function press any other key except the arrow keys gas purge or function select key Selection of English or Metric Speed Display Units Pressing both the Gas Purge key and then timer select key at the same time causes the Speed display units to toggle between IPM no decimal point displayed and m m a decimal point displayed If the speed dis play units were IPM then they will change to m m If the speed display units were m m then they will change to IPM If the display is showing the volts trim or one of the timers when the keys are pressed the display will be changed to weld speed to indicate the selected speed display units Run In Selection Pressing both the Gas Purge key then the Cold Feed key at the same time causes Run In function to toggle on or off as indicated by the Run In indicator light turning on or remaining off in the function select sequence As shipped the Run In function is off with a fixed setting of 50 IPM 1 27 m min Therefore the Run In indicator light will not sequence with the function select key but the fixed setting will still be used for actual Run In speed Activati
46. but not when in Gun or A If any of these continuity tests fail repair or replace switch or switch harness to cor rect problem Otherwise replace Control board See procedure for replacing PC boards a Place local dual procedure switch in Gun posi tion and if a remote control kit is attached place its dual procedure switch in Gun position also b If a remote control kit is attached remove it If this solves the problem refer to Problem 19 c Make sure parameters on power source display such as WFS match those on wire feeder display If not refer to Problem 14 d Remove switch Make sure there is continuity between switch pins with switch closed and no continuity with switch open If either of these tests failed repair or replace switch e Remove optional gun dual procedure switch and disconnect harness plug from J2 on Control board Check that there is continuity between pin A of receptacle J17 and pin 13 of plug P2 Check that there is continuity between pin C of recepta cle J17 and pin 4 of plug P2 Check no continuity between pins A and C of receptacle J17 If any of these continuity tests fail repair or replace switch amphenol J17 or switch harness f Perform step c of Problem 17 g Replace Control PC board See procedure for replacing PC boards If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Fi
47. cautions A WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring When inching with gun trigger electrode and drive mechanism are hot to work and ground and could remain energized several seconds after the gun trigger is released Turn OFF input power at welding power source before installation or changing drive roll and or guide tubes Welding power source must be connected to system ground per the National Electrical Code or any applicable local codes Only qualified personnel should perform this installation Observe all additional Safety Guidelines detailed throughout this manual Attaching Wire Reel Stand The mounting hardware for mounting the wire reel stand is included with the wire feeder Screws and washers are inserted in their respective mounting holes To connect 1 Remove the three 3 8 9 5 mm hex head screws from the back of the wire feed unit 2 Place the wire reel stand mounting bracket in posi tion against the back of the wire feed unit 3 Replace and tighten the screws The long screw and plain washer go into the top hole SYNERGIC 7 amp 7H LINCOLN A 6 Wire Feed Drive Roll and Guide Tube Kits NOTE The maximum sizes the Synergic 7 will feed satisfactorily are the 3 32 2 4mm cored and 1 16 1 6mm solid electrodes The maximum sizes the Synergic 7H will feed satisfactorily are the 045 1 2mm cored
48. cking nut and repeat the above steps 4 After the outgoing pressure is set determine how many turns away from full pressure the setting is Set both idle roll tensions to this setting Engage both idle rolls before welding In most applications best wire feeding will occur when both idle roll pressures are set the same Gas Guard Regulator Setting 1 With the gas supply shut off the Gas Guard regu lator flow adjusting key should be set to maximum full clockwise which is rated to be 60 SCFH 28 Its min 2 Adjust gas supply flow rate for a level higher than will be required then adjust Gas Guard flow adjusting key counterclockwise to the desired gas flow rate SYNERGIC 7 amp 7H LINCOLN P B 10 Making a Weld 1 Use only Power Wave model synergic power sources 2 Properly connect the electrode and work leads for the correct electrode polarity 3 Use Mode Selection key to set desired operating mode Refer to Mode Selection section 4 Use Function Select and Arrow keys to set desired Run in and encoder knob to set Weld Feed Speed Set for each procedure if using a Dual Procedure function See the appropriate sections for adjust ing procedures 5 Adjust the voltage or percent trim if desired for each procedure if using a Dual Procedure function using the encoder knob in Volts Trim function refer to Volts Trim section The final setting can be adjusted according to the desired arc vo
49. control cable with a 14 pin plug and 2 0 67 mm2 electrode cable with Twist Mate connector It is rated at 350 amps 6096 duty cycle and is available in lengths of 7 ft 2 m 17 ft 5 m 33 ft 10 m and 50 ft 15 m K677 7 Used with Power Wave 350 Similar to K651 but includes a gas hose with a 5 8 18 male fitting for the Synergic 7 inlet It is rated at 350 amps 60 duty cycle and is available in 7 ft 2 m length K650 Used with Power Wave 350 and Synergic 7 7H with water quick connection Similar to K651 but includes a gas hose with a 5 8 18 male fitting for the Synergic 7 inlet and water hoses with quick connect male fittings to connect between the water cooler and the Synergic 7 water connections lt is rated at 350 amps 60 duty cycle and is available in lengths of 7 ft 2 m 17 ft 5 m 33 ft 10 m and 50 ft 15 m K642 Control Cable Only Consists of an 8 conduc tor control cable with a 14 pin control cable plug with out electrode cable and is available in lengths of 7 ft 2 m 17 ft 5 m 25 ft 7 6 m 33 ft 10 m and 50 ft 15 m K643 Control Cable Extension Consists of an 8 conductor control cable with 14 pin connectors on each end for extending the control cable between the power source and the control cables Available in lengths of 17 ft 5 m 25 ft 8 m 33 ft 10 m and 50 ft 15 m SYNERGIC 7 amp 7H LINCOLN C2 ACCESSORIES LZ UNIVERSAL WIRE REEL STAND K1524 1
50. could remain energized several seconds after the gun trigger is released Turn OFF input power at welding power source before installation or changing drive roll and or guide tubes Welding power source must be connected to system ground per the National Electrical Code or any applicable local codes Only qualified personnel should perform this installation 0 Observe all additional Safety Guidelines detailed throughout this manual Standard 4 Roll Kits KS655 and KS656 1 Turn OFF welding power source 2 Release both quick release levers by sliding the levers sideways into the open positions Remove clamping screw amp clamping collar from the drive shaft closest to the incoming side of the feed er Install drive roll onto keyed shaft Do not exceed the maximum wire size rating of the wire drive Replace collar and tighten clamping screw el Back out the set screw for the middle guide tube Install the middle guide tube and slide it up against the drive roll DO NOT TIGHTEN THE MIDDLE GUIDE AT THIS TIME D Install the outgoing drive roll following the same procedure as steps 3 amp 4 7 Center the middle guide between the two drive rolls and tighten in place SYNERGIC 7 amp 7H LINCOLN A 7 INSTALLATION A 7 8 Back out the screws for the incoming and outgoing guide tubes 9 Install the longer guide tube in the rear hole near the incoming drive roll Slide the tube in until
51. d these models are setup for minimum rated fixed Run In speed with dis play function deactivated They may be user selected to activate or deactivate adjustable Run In display See section for selection of Run In and resetting fixed Run In speed Wire will be fed at the Run In speed rate until arc current begins to flow Once arc current flows wire will be fed at the Weld speed rate Decreasing Run In speed below its lower limit using the down arrow key causes the display to read This indicates that the Run In speed will be kept the same as the weld speed setting You can reset a different Run In speed simply by pressing the up arrow key The Run In speed will also be the same as the weld speed setting if rapid restrike welding applications are used where the arc is restruck in a fraction of a second after the previous welding arc was stopped Bottom Light Indicates Weld Feed Speed WFS Function has been selected and the weld speed setting is being dis played in IPM or m m see section for English or Metric speed display The range of Weld Feed Speed is synergically set by the power source for the process being used and is adjustable using the Wire Feed Speed encoder knob on the front of the Synergic 7 Control If selected see Memory Ammeter Selection section the bottom light will blink while welding indicating that the dis play has been selected to display welding amps The last welding current displa
52. der Check continuity between socket G of 8 socket plug and pin G of 14 pin plug of the input cable Check continu ity between socket H of 8 socket plug and pin H of 14 pin plug of the input cable Replace cable if no continuity Remove molex plug P1 from J1 on Control PCB Check continuity from pin G of 8 pin receptacle on wire feeder to pin 4 of plug P1 and from pin H of 8 pin receptacle to pin 3 of plug P1 If no continuity then repair harness otherwise replace Control PCB See procedure for replacing PC boards When a remote control kit is connected to the Wire Feeder the WFS and Volts Trim knobs of the Wire Feeder become inactive and the WFS and Volts Trim knobs of the remote control kit must be used b Broken harness wire s or harness b Check for continuity between correspond disconnected from Encoder board s or Control board c Defective Encoder boards and or Control board 44 CAUTION ing harness leads of molex plug P2 on Control board and molex plugs P12 and P13 on Encoder boards refer to wiring dia gram If any of these continuity tests fail repair or replace harness If b is not the problem and neither the WFS or Volts Trim knobs are properly adjusting then replace the Control board If one of the knobs is properly adjusting plug the harness P12 or P13 from the working board into the nonfunctional board If the previously nonfunctional board is now work ing then replace the Contr
53. des 2 step trigger 4 step trig ger and spot Three functions can be selected Volts or Trim Preset arc memory voltmeter Run in speed and weld speed IPM or m min or memory ammeter In addition when 4 step trigger mode is selected crater fill WFS is also adjustable Up to three timers are available depending on the mode preflow postflow and spot and 5 acceleration rates are selectable as well as 6 Burnback settings The Synergic 7 is available in 2 models Ordering Speed Range Wire Size Range Information IPM m m IN MM 4 Roll 50 770 025 3 32 1 25 19 5 0 6 2 4 K631 4 Synergic 4 Roll 80 1200 025 045 7H 2 00 30 5 0 6 1 2 RECOMMENDED PROCESSES AND EQUIPMENT SE The Synergic 7 wire feed unit has the following wire feeding capabilities a Feeds 025 1 16 0 6 1 6mm solid wire for gas metal arc processes b Feeds 045 3 32 1 2 2 4mm cored wire for Outershield GMA or Innershield processes up to 5 64 2 0 mm The Synergic 7H wire feed unit has the following wire feeding capabilities a Feeds 025 045 0 6 1 2mm solid wire for gas metal arc processes INSTALLATION A 2 b Feeds 045 1 2mm cored wire for Outershield GMA or Innershield processes Recommended power sources are The Lincoln Electric Company Synergic type Invertec Power Wave power sources with 42VAC auxiliary power and a 14 pin connector receptacle STANDARD FEATURES Wire
54. e Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS A FOR ENGINE powered equipment 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 ca 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors 23 ELECTRIC AND ES MAGNETIC FIELDS e may be dangerous 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines 1 c Do not add the fuel near an open flame welding arc o
55. earby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 3 Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating products 5 6 LINCOLN Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions
56. ease No maintenance of the two position adjustable brake is needed If the brake shoe wears through to the metal replace the brake assembly Wire Reel Mounting Readi Reels 10 through 44lb 4 5 20kg Spools and 50 60lb Coils with K1504 1 Adapter No routine maintenance required Do not lubricate 2 51mm spindle Avoiding Wire Feeding Problems Wire feeding problems can be avoided by observing the following gun handling procedures a Do not kink or pull cable around sharp corners b Keep the electrode cable as straight as possible when welding or loading electrode through cable c Do not allow dolly wheels or trucks to run over cables d Keep cable clean by following maintenance instructions e Use only clean rust free electrode The Lincoln electrodes have proper surface lubrication f Replace contact tip when the arc starts to become unstable or the contact tip end is fused or deformed g Do not use excessive wire spindle brake settings Periodic Maintenance Wire Drive Motor and Gearbox Every year inspect the gearbox and coat the gear teeth with a moly disulfide filled grease Do not use graphite grease Every six months check the motor brushes Replace them if they are less than 1 4 long Gun and Cable Maintenance See appropriate Operators Manual SYNERGIC 7 amp 7H LINCOLN E 1 TROUBLESHOOTING E 1 A WARNING Service and Repair should only be performed by Lincoln Electric F
57. eld Service Facility for technical troubleshooting assistance before you proceed SYNERGIC 7 amp 7H LINCOLN B TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual 19 Dual procedure switch of remote la Local dual procedure switch is not Ja Local dual procedure switch should be control kit is not functioning prop erly 20 Purge key does not turn on sole noid but trigger closure does 21 Cold Feed key does not turn on wire feed motor but trigger clo sure does 22 Display and or indicator lights do not change when the arrow or Select keys are pressed in Gun position and or an optional gun dual procedure Switch is attached Faulty communication between wire feeder and remote control kit Faulty dual procedure switch wiring harness or PC board in remote control kit a Defective keypad or Display PC board is defective a Defective keypad or Display PC board is defective a Defective keypad or Display PC board 44 CAUTION in Gun position if a remote control kit is attached If an optional gun dual procedure switch is attached and both the local dual procedure switch and remote s dual procedure switch are in Gun position then the optional gun dual procedure switch is used to Switch between procedures A and B If knobs on remote control kit are not operating properly refer to Problem 16 Disconnect harness plug from Remote PC board Check t
58. enance and Troubleshooting Guide Problem 24 Indicates problem in EPROM assembly See Troubleshooting Guide Problem 24 Indicates problem in microprocessor RAM See Troubleshooting Guide Problem 24 Indicates various system problems XX will be a number from 01 to 10 Turn off power to feeder Wait 5 seconds Turn power back on If error persists see Troubleshooting Guide Problem 24 If error does not reoccur be sure to check all wire feed speed accelera tion and timer settings before you proceed EEPROM error Usually occurs at power up Indicates one or more of the recalled settings is out of acceptable limits Press any key to return to normal operation Be sure to check all wire feed speed acceleration and timer settings before you proceed Indicates that the Grounding Lead Protector circuit was activated due to excessive current flow into the wire feeder frame When the Grounding Lead Protector circuit is activated the wire feeder is disabled i e the trigger out put to the power source is opened up the motor is stopped and the gas solenoid is turned off To resume normal operation release the trigger make sure that the elec trode is not touching the wire feeder frame and then either press a key on the keypad or close the trigger See Problem 24 in the Troubleshooting Guide C 1 OPTIONAL FEATURES DRIVE ROLL AND GUIDE TUBE KITS Steel Wire Sizes 4 Roll 068 3 32 1 7 2 4mm Cored KS655 3 32 4
59. er source is blown short in 41 and 42 circuit Check for or tripped shorted motor Replace fuse or reset circuit breaker c Display or Control PC board is Observe LED mounted on Control PC bad board It should blink on and off at a controlled rate of 1 second ON and 1 second OFF If so then replace Display PC board If not replace Control PC board See Procedure for Replacing PC boards 44 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed SYNERGIC 7 amp 7H LINCOLN E 11 TROUBLESHOOTING E 11 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION 24 Display shows any of the following H a Voltmeter function is selected and arc la Normal operation Voltmeter only reads 0 voltage is gt 80 VDC a Run in speed is selected but is dis a Run in speed is now weld speed To re abled enable Run in speed simply press the increase arrow key a See Problem 5 or see Section on a XX indicates time in seconds before unit Safety Precautions will automatically reset a EEPROM error a Parameter recalled at power up was out of range Press any key to reset Check all settings before proceeding to weld If this condition persists then ROM assembly X8 on t
60. et Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines soud er parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se pro t ger contre les chutes dans le cas ou on recoit un choc Ne soudage Utiliser des lunettes avec crans lateraux dans les zones ou l on pique le laitier
61. h Power Wave 450 500 and Synergic 7 7H with water quick connection Similar to K649 but includes a gas hose with a 5 8 18 male fitting for the Synergic 7 inlet and water hoses with quick connect male fittings to connect between the water cooler and the Synergic 7 water connections It is rated at 500 amps 60 duty cycle and is available in lengths of 7 ft 2 m ACCESSORIES C 1 17 ft 5 m 25 ft 7 6 m 33 ft 10 m and 50 ft 15 m K648 Used with Power Wave 450 Consists of an 8 conductor control cable with a 14 pin plug and a 4 0 107 mm electrode cable with stud terminal It is rated at 500 amps 60 duty cycle and is available in lengths of 7 ft 2 m 17 ft 5 m 25 ft 7 6 m 33 ft 10 m and 50 ft 15 m K676 Used with Power Wave 450 Similar to K648 but includes a gas hose with a 5 8 18 male fitting for the Synergic 7 inlet It is rated at 500 amps 60 duty cycle and is available in lengths of 7 ft 2 m 25 ft 7 6 m and 50 ft 15 m K640 Used with Power Wave 450 and Synergic 7 7H with water quick connection Similar to K648 but includes a gas hose with a 5 8 18 male fitting for the Synergic 7 inlet and water hoses with quick connect male fittings to connect between the water cooler and Synergic 7 water connections It is rated at 500 amps 60 duty cycle and is available in lengths of 7 ft 2 m 25 ft 7 6 m and 50 ft 15 m K651 Used with Power Wave 350 Consists of an 8 conductor
62. hat there is conti nuity between plug pins 7 and 8 when dual procedure switch is in position A but not when in Gun or B Now check that there is continuity between plug pins 6 and 7 when dual procedure switch is in position B but not when in Gun or A If any of these tests failed repair or replace Switch or switch harness Otherwise replace Remote PC board a Check continuity between sockets 5 and 1 of keypad connector when purge key is closed If not then replace keypad otherwise replace Display PC board See Procedure for Replacing PC boards Check continuity between sockets 4 and 1 of keypad connector when Cold Feed key is closed If not then replace keypad otherwise replace Display PC board See Procedure for Replacing PC boards Ring out keypad Replace if defec tive If not then replace Display PC board See Procedure for Replacing PC boards If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed SYNERGIC 7 amp 7H LINCOLN E 10 TROUBLESHOOTING E 10 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED ee CAUSE COURSE OF ACTION a Power source is OFF a Turn ON power source b Feeder supply fuse or circuit b Check input cable and feeder unit for breaker at pow
63. he Control PC board is faulty Replace Control PC board See procedure for replacing PC boards a Where XX is a number from 1 to 10 a Turn off power to feeder Wait for 5 sec System error onds Turn power back on If EXX is dis played again then ROM assembly X8 on the Control board is faulty Replace Control PC board See procedure for replacing PC boards a EPROM checksum error a Turn off power to feeder Wait 5 seconds Turn power back on If EP is displayed again then ROM assembly X8 on Control PC board is faulty Replace Control PC board See procedure for replacing PC boards a Microprocessor RAM error a Turn off power to feeder Wait 5 seconds Turn power back on If uP is displayed again then ROM assembly X8 on the Control PC board is faulty Replace Control PC board See procedure for replacing PC boards a Grounding Lead Protector circuit is a To return to normal operating mode activated due to excessive current release the trigger and press any key on flow into the wire feeder frame the keypad If GLP is still displayed or if it appears again before the trigger is closed then proceed to step b Otherwise before proceeding to weld make sure that the electrode is not touching the wire feed er frame b Faulty GLP reed switch harness or b Replace GLP reed switch CR1 if it is Control PCB shorted Check the wiring harness between GLP reed switch CR1 and the Control board Repair or replace fau
64. his manual 3 Poor arc striking with sticking or plast offs weld porosity narrow a Improper procedures or tech niques a See Gas Metal Arc Welding and ropy looking bead or elec trode stubbing into plate while welding Tip seizes in diffuser Unit shuts off while welding and HXX appears on display Drive roll does not turn although arc voltage is present and sole noid is on b Improper gas shielding a Tip overheating due to prolonged or excessive high current and or duty cycle welding a See Problem 1 b Defective wire feed motor or gearbox a Defective wire feed motor or con trol PC board 44 CAUTION Guide GS 100 b Clean gas nozzle Make certain that gas diffuser is not restricted Make certain that gas cylinder is not empty or turned off Make certain gas solenoid valve is operat ing and gas flow rate is proper Remove gun liner and check rubber seal for any sign of deterioration or damage Be sure set screw in brass connector is in place and tightened against the liner bush ing Do not exceed current and duty cycle rating of gun A light application of high temper ature antiseize lubricant such as Lincoln E2607 Graphite Grease may be applied to tip threads Correct problems causing motor overload Replace Set Run in speed to maximum Disconnect wire drive plug P5 from PC board Measure voltage across pin 1 of J5 and pin 2
65. ight Indicates 4 step lock trigger mode This mode may be selected to include crater fill or weld current interlock Bottom Light Indicates spot weld mode O V voLTSITRM olo RUNN e ojo wrs e ulft o e o e suc O JL CRATER SPOT SYNERGIC 7 amp 7H LINCOLN A 4 Function Select key enables operator to choose which function will be displayed as shown by the appropriate indicator light Pressing the key causes lights to sequence top to bottom starting from the current indicated position The function displayed will be adjustable with the rotating encoder controls or arrow keys Adjusting either encoder knob automatically transfers dis play and indicator light to the function being adjusted Top Light Indicates display of preset voltage or percent trim when not welding and arc voltage while welding as indicated by top light blinking and continues for 5 sec onds after the weld has stopped memory vpltmeter The power source automatically determines whether preset voltage or percent trim will be displayed and adjustable with Volts Trim rotating encoder control Middle Light Indicates Run in speed is being displayed As shipped these models are setup for a 50 IPM 1 27m min fixed run in speed with display function deac tivated They may be user selected to activate or deacti vate adjustable Run in display and setting with arrow keys Bottom Light Indicates Weld Feed Speed WFS is
66. ime default Oms if required to prevent electrode from sticking in weld puddle at finish of weld Spot Mode Allows a single timed weld cycle each time the gun trigger is held closed Duration 0 2 9 9 seconds is set by the Spot ON timer Digital Memory Voltmeter Displays arc voltage from 0 to 80V DC when welding gun trigger is activat ed with automatic polarity indication for positive or negative electrode The last welding voltage moni tored at end of weld is displayed for 5 seconds after weld has stopped This allows checking actual volt age after weld has stopped Digital Memory Ammeter Weld Feed Speed WFS display may be selectable to display welding amps only while welding and the last welding amps monitored at the end of the weld will be displayed for 5 seconds after the weld has stopped This allows checking actual weld current after the weld has stopped Power down Save All settings including mode Run in speed cold feed speed crater speed weld speed timers English Metric units and acceleration are automatically saved when power is removed This feature does not require batteries and when power is restored it will automatically return all settings to the state they were in when power was removed However the power source may overwrite any or all of these parameters after Power Up Recall is com plete SYNERGIC 7 amp 7H LINCOLN A 4 COLD FEED GAS PURGE V zem
67. l Installation and Shielding Gas Connections sections for instructions K640 K641 or K650 Input Cable Assembly Water amp Gas See Electrical Installation Water Connections and Shielding gas connections sections for instruc tions K376 50 60 Lb Wire Reel Mounting Stand without dust shield and K303 50 60 Lb Wire Reel Mounting Stand with dust shield The assembly includes a framework to which is attached the 50 60 Ib wire reel a mounting spindle a lift bail and a cable clamp for fastening the input cable assembly It is easily mounted to the basic wire feed unit by three bolts The reel mounting spindle is the pull knob type with a built in brake The brake pad is adjustable for proper braking at low or high wire feed speeds SYNERGIC 7 amp 7H LINCOLN A 11 Wire Reel Dust Shield for K376 50 60 Lb Wire Reel Mounting Stand If the user desires to protect the wire from falling dirt and dust there is a shield avail able to cover the wire reel Order part number S14543 Instructions are included with the kit Wire Reel Dust Shield Door for K303 and K376 when equipped with an S14543 shield In extremely dusty and dirty locations this door kit can be added to those units having the shield kit 814543 This door kit includes a hinged door and sliding bottom seal When these parts are attached to the reel support per the instructions included the unit becomes a completely enclosed housing Order part number M1
68. l completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life 44 CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment TABLE OF CONTENTS Page DECIES NE Section A RE ale ET ee A 1 General RE le TEE A 2 Recommended Processes and Equipment sse A 2 Standard TEE A 2 Keypad and Display Description A 4 Safety Precalltions c iiir iere ER eege a pha ze ED seed A 5 Installation of the Synergic 7 Components A 5 Attaching Wire Reel Gtanmd nan eene A 5 Wire Feed Drive Roll and Guide Tube Kits A 6 Standard 4 Roll Kits KS655 and KS656 sse A 6 Procedure to Install Drive Roll and Guide Tubes conos A 6 Gun and Cable Assemblies eene A 7 EIERE UE A 7 Innershield GUNS itii ea annee aa A 7 Gun and Cable Connections ss A 7 Wire Feeder to Gun A 7 For GMA GUN Cables sacs iei sn eei Dr x ceti E Te dete agde A 7 Synergic 7 Water Connections eene A 8 GMAW Shielding as toot teu eee ERR ati A 8 Gas Guard Regulator AA A 8 Seilen ET e ME
69. ld elec trode coil from the conductor cable by either pulling it out at the nozzle end of the gun or by using the follow ing procedure 1 Cut the end of the electrode off at the gun end Do not break it off by hand because this puts a slight bend in the wire making it difficult to pull it back through the nozzle E Disconnect the gun cable from the gun connector on the Synergic 7 Wire Feed Unit and lay the gun and cable out straight e Using pliers to grip the wire pull it out of the cable from the connector end 4 After the electrode has been removed reconnect the gun cable to the Synergic 7 Load a new reel of electrode per the instructions in the Wire Reel Loading sections Wire Feed Overload Protection The Synergic 7 has solid state overload protection of the wire drive motor If the wire drive motor becomes overloaded for an extended period of time the protec tion circuitry turns off the power source wire feed and solenoid and then displays H30 This indicates the wire drive motor is overloaded and the number indi cates the time remaining in seconds before the unit will automatically reset The number continues to decrement every second until it reaches O At that time the unit resets automatically and the previous display will return indicating the unit is ready to oper ate again Overloads can result from improper tip size liner drive rolls or guide tubes obstructions or bends in the gun cable feeding
70. le PR CAUTIONS DE S RET POUR partie du corps LES MACHINES SOUDER 3 Un coup d arc peut tre plus s v re qu un coup de soliel TRANSFORMATEUR ET REDRESSEUR donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayonnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dis positif de montage ou la piece souder doit tre branch une bonne mise la terre Prot ger l autre personnel travaillant proximit au 2 Autant que possible l installation et l entretien du poste soudage l aide d crans appropri s et non inflamma bles seront effectu s par un lectricien qualifi 3 Avant de faires des travaux l interieur de poste la 4 Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pantalons sans revers et chaussures montantes LINCOLN debrancher l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 v v for selecting a QUALITY product by Lincoln Elec
71. ltage while welding 6 Use Timer Crater Select and Arrow keys to set desired timers or crater speed if 4 step trigger with Crater fill has been selected Refer to the Timer Crater section 7 Feed the electrode through the gun and cable and then cut the electrode within approximately 38 9 5mm of the end of the contact tip for solid wire and within approximately 75 19mm of the extension guide for cored wire 8 Connect work cable to metal to be welded Work cable must make good electrical contact to the work The work must also be grounded as stated in Arc Welding Safety Precautions A WARNING When using an Open Arc process Z itis necessary to use correct eye ME head and body protection 9 If used be sure shielding gas valve is turned on 10 Position electrode over joint End of electrode may be lightly touching the work 11 Lower welding helmet close gun trigger and start welding Hold the gun so the contact tip to work distance gives the correct electrical stickout as required for the procedure being used OPERATION B 10 12 To stop welding release the gun trigger and then pull the gun away from the work after the arc goes out and Postflow time if used is over 13 If necessary to optimize arc starting adjust wire speed acceleration and or Run In speed See the appropriate sections for adjusting procedures Wire Reel Changing At the end of a coil remove the last of the o
72. lty harness If the reed switch and the wiring harness are both OK then replace the Control board 44 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed SYNERGIC 7 amp 7H LINCOLN B E 12 TROUBLESHOOTING Procedure for Replacing PC Boards 44 WARNING e ELECTRIC SHOCK can kill Have a qualified individual install and service this equipment Turn the power source input power off at the disconnect switch before work ing on this equipment Do not touch electrically hot parts Before replacing a PC board which is suspected of being defective visually inspect the PC board in ques tion for any electrical or mechanical damage to any of its components and conductors on the back of the board a If there is no visible damage to the PC board install a new one and see if this remedies the prob lem If the problem is remedied reinstall the old PC board to see if the problem still exists If it does no longer exist with old PC board 1 Check the PC board harness connector pins for corrosion contamination or looseness 2 Check leads in the plug harness for loose or intermittent connection b If PC board is visibly damaged electrically before possibly subjecting the new PC board to the same cause of failure check for p
73. lug connector P2 from J2 in remote control kit Check conti nuity between pin 1 of P2 and pin 2 of P1 between pin 2 of P2 and pin 3 of P1 between pin 3 of P2 and pin 4 of P1 and between pin 4 of P2 and pin 5 of P1 If any of these tests failed repair or replace remote wiring har ness e Faulty wire feeder harness or Remove plug from J2 on Control remote cable receptacle board of wire feeder and remove remote cable from wire feeder Check continuity between socket A of remote receptacle J16 and pin 14 of plug P2 between socket B of remote recepta cle and pin 7 of plug P2 between socket C of remote receptacle and pin 15 of plug P2 and between socket D of remote receptacle and pin 16 of plug P2 If any of these tests failed then repair or replace wiring harness Check continuity between either of the four pins of receptacle J16 If there is continuity between either of the pins then receptacle is faulty f Faulty Control board or Remote Try replacing Remote PC board If PC board this does not solve the problem then replace Control board of wire feeder See procedure for replacing PC boards 44 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed SYNERGIC 7 amp 7H LINCOLN B E 8 TROUBLESHOOTING E 8 Observe all Safe
74. mmer on the spinner nut arms 44 CAUTION Always be sure the free end of the coil is securely held while the tie wires are being cut and until the wire is feeding through the drive rolls Failure to do this will result in back lashing of the coil which may tangle the wire A tangled coil will not feed It must be untangled or discarded 8 Cut and remove only the tie wire holding the free end of the coil Insert the free end into one of the holes in the cover and secure it by bending it back Cut and remove the remaining tie wires 9 Replace the reel on the wire feeder Grasp the shaft knob pull it out and swing it across the reel hub locking the reel in place FIGURE B 2 LOADING A 50 OR 60 LB COIL SPINNER NUT 9 a SF COVER SS PLATE SLOTS CARDBOARD TIE WIRE REEL i SPRING Pm LOADED ARM SYNERGIC 7 amp 7H LINCOLN P B 8 OPERATION B 8 WIRE REEL LOADING 50 AND 60 LB COILS K1524 1 UNIVERSAL WIRE REEL STAND TO MOUNT A 50 to 60 Ib 22 7 to 27 2 kg COIL USING K1504 1 COIL REEL FOR 50 to 60 Ib READI REELS A K438 READI REEL ADAPTER MUST BE USED The spindle should be located in the UPPER mount ing hole 1 With the K 1504 1 Coil Reel mounted on the 2 in 51 mm spindle or with reel laying flat on the floor loosen the spinner nut and remove the reel cover See Figure B 3 2 Before cutting the tie wires place the coil of elec trode on the reel so
75. ng spring pops up fully A WARNING Check to be sure the Retaining Spring has fully returned to the locking position and has SECURELY locked the Readi Reel Cage in place Retaining Spring must rest on the cage not the welding elec trode 9 To remove Readi Reel from Adapter depress retaining spring tab with thumb while pulling the Readi Reel cage from the molded adapter with both hands Do not remove adapter from spindle FIGURE B 1b Retaining Collar 2 IN OD SPINDLE ADAPTER RETAINING SPRING GROOVES READI REEL INSIDE CAGE WIRES RELEASE BAR SYNERGIC 7 amp 7H LINCOLN P B 6 OPERATION TO MOUNT 10 TO 44 Ib 4 5 to 20 kg SPOOLS 12 in 300 mm DIAMETER OR 13 14 Ib 6 kg INNERSHIELD COILS The spindle should be located in the lower mounting hole of the K1524 1 Universal Stand if used For 8 in 200 mm spools a K468 spindle adapter must first be slipped onto the spindle For 13 to 14 Ib 6 kg Innershield coils a K435 Coil Adapter must be used 1 ELECTRODE Depress the Release Bar on the Retaining Collar and remove it from the spindle NOTE Earlier spindles used a threaded collar See Figure B 5a or B 5b Place the spool on the spindle making certain the spindle brake pin enters one of the holes in the backside of the spool Be certain the wire comes off the reel in a direction so as to de reel from the bottom of the coil Re install the Retaining Collar Make sure that
76. oard See procedure for replacing PC boards 44 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed SYNERGIC 7 amp 7H LINCOLN B E 6 TROUBLESHOOTING E 6 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION a This is normal as only the WFS and a Refer to operation section of this manual volts trim knobs will adjust these settings 12 Arrow keys do not change Weld speed or volts trim 13 WFS knob does not change Run in speed 14 WFS and preset Volts Trim para meters on wire feeder display do not match those on power Source display 15 Display does not change when WFS and or Volts Trim knobs are turned a This is normal as only the arrow keys will adjust this setting a Power source is defective b Problem with serial communica tions in control cable c Problem with wire feeder harness or Control PCB a A remote control kit is connected 8 Refer to operation section of this manual 8 If parameters on power source and wire feeder display match when wire feeder is connected to the other input receptacle 1 or 2 of power source then power source is defective Disconnect input cable from power source and wire fee
77. ol board other wise replace the nonfunctional Encoder board See procedure for replacing PC boards If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed SYNERGIC 7 amp 7H LINCOLN B E 7 TROUBLESHOOTING E 7 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION 16 Wire feeder s display does not a Loose connection to Remote con a Make sure that remote cable connec change when WFS and or trol receptacle J16 tions are tight Volts Trim knobs of the remote b Faulty Remote PC board If either the WFS knob the Volts Trim control kit are turned knob or the dual procedure switch of the remote control kit is operating properly then replace the Remote PC board c Faulty remote cable Remove remote cable from wire feed er and unplug connector P2 from J2 in remote control kit Check continuity between pin 1 of J2 and socket B of remote receptacle between pin 2 of J2 and socket A of remote receptacle between pin 3 of J2 and socket D of remote receptacle and between pin 4 of J2 and socket C of remote recepta cle If any of these continuity tests fail then repair or replace remote cable d Faulty remote wiring harness Remove plug from J1 on Remote PC board and unp
78. on of adjustable Run In speed using the above dual key press will permit Run In speed to be adjusted with the arrow keys See Section 3 3 4 and the Run In indicator light will return to the function key sequence Re pressing the above dual key again removes the Run In light from the function key sequence but replaces the fixed Run In speed with the adjusted Run In speed setting until readjusted B 4 4 Step Trigger Mode Selection Y Pressing both the Gas Purge key and then the Trigger mode select key causes the 4 step mode light to GAS PURGE turn on and will toggle the 4 step 2 STEP y 4 trigger mode between SR o 4 step with current interlock as shipped 4 STEP 44 14 Crater light will not turn on Lock and 4 step with crater fill SPOTee e0 Crater light will turn on for crater speed set ting with arrow keys See Mode Selection and Display Control Keys sections Memory Ammeter Selection Pressing both the Gas Purge key then the Up Arrow key at the same time causes the WFS light to blink for about 3 seconds while display GAS PURGE shows weld amps reading with elec trode polarity symbol This indicates that while welding the display will Procedure Selector Switch D show welding amps indicated by blinking WFS indicator light which continues for 5 seconds after the weld is stopped memory ammeter before returning to displaying WFS light not blinking Pressing both the G
79. ossible shorts opens or grounds caused by 1 Frayed or pinched lead insulation 2 Poor lead termination such as a poor contact or a short to adjacent connection or surface 3 Shorted or open motor leads or other external leads 4 Foreign matter or interference behind the PC boards c If PC board is visibly damaged mechanically inspect for cause then remedy before installing a replacement PC board If there is damage to the PC board or if replacing PC board corrects problem return it to the local Lincoln Electric Field Service Shop SYNERGIC 7 amp 7H LINCOLN E 12 Jequunu epoo jueuudinbe ay BAIN 3ueureoe dei e 104 juauuedag 2911S ay 0 ajum eidelt si WesGeIp u y sjeued einsoj oue ay Jo euo uo euiuoeui y episui pejsed si epoo jejnonaed e 104 ureJBerp 2upede sy Jenueui siy Aq paJeAoo saulyoeu je 104 e1eJnooe eq jou Aew y 7 21661 LL A ae a HOLIMS 38nd390Hd c m0 D I Wna WwNOlLdO NS f ue d 318v9 310 38 Hike Gell 00 9d gt 00S Y18 90 gt ul8 428 ad gt 408 gir XIGWASSYV CIOYOL 20 OH1NOO ALOWSY 3unaaooud WNC 1YNOILdO ON E JISVO gir TOHINOO NN9 age sim Lie 979 lt 9 DIAGRAMS 009 lt ge SLIOA sos lt e 915 lt 9 216 Ge EC lf lt ce G09 lt z onde _ _ 5 HOLIMS 38nd3908d WAG WOO o v 34Nd390Hd 8 3unaao0ud O gt Nid Eld Lid ld Old HOLO3NNOO NNO ALVW LSV4 OL LOANNOO
80. pin B and the 8 socket plug pin E per diagram below r B GND Ba E GND 8 PIN PLUG FRONT VIEW K649 Used with Power Wave 450 500 Consists of an 8 con ductor control cable with a 14 pin control cable plug and a 4 0 107mm electrode cable with Twist Mate connector It is rated at 500 amps 60 duty cycle and is available in lengths of 7 ft 2 m 17 ft 5 m 25 ft 7 6 m 33 ft 10 m and 50 ft 15 m K675 Used with Power Wave 450 500 Similar to K649 but includes a gas hose with a 5 8 18 male fitting for the Synergic 7 inlet It is rated at 500 amps 60 duty cycle and is available in lengths of 7 ft 2 m 25 ft 7 6 m and 50 ft 15 m K641 Used with Power Wave 450 500 and Synergic 7 7H with water quick connection Similar to K649 but includes a gas hose with a 5 8 18 male fitting for the Synergic 7 inlet and water hoses with quick connect male fittings to connect between the water cooler and the Synergic 7 water connec tions It is rated at 500 amps 60 duty cycle and is avail able in lengths of 7 ft 2 m 17 ft 5 m 25 ft 7 6 m 33 ft 10 m and 50 ft 15 m K648 Used with Power Wave 450 Consists of an 8 con ductor control cable with a 14 pin plug and a 4 0 107 mm electrode cable with stud terminal It is rated at 500 amps 60 duty cycle and is available in lengths of 7 ft 2 m 17 ft 5 m 25 ft 7 6 m 33 ft 10 m and 50 ft 15 m 14 PIN PLUG FRONT VIEW K676 Used with
81. ping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate cir cuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c LINCOLN CYLINDER may explode if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physic
82. po e Prot gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und K r perschutz e Use protec o para a vista ouvido e corpo A HRUSHICRBRELTE EU OMAR HRSRSORENE ex 19 Sal RSA HEHA daig die ule Lilly gupay alg ene Ai EE READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n e Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases e Gardez la t te l cart des fum es e Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch e Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha se
83. r when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz ing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to In some cases it may be necessary to remove safety nes Ro minimize exposure to EMF fields from the welding circuit guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 4 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan ew Do not attempt to override the governor or idler by pushing on the throt
84. s light will be skipped over in the selection sequence Increase Arrow key increases the setting of the parameter selected to be displayed except Wire Feed Speed and Volts Trim which are controlled by the encoder knobs Decrease Arrow key decreases the setting of the parameter selected to be displayed except Wire Feed Speed and Volts Trim which are controlled by the encoder knobs Arrow Keys use the Accelerating Digit method for setting changes where holding the arrow key causes setting change rate to accelerate from slow to fast Releasing arrow key resets to slow setting change E GAS PURGE O V voam e olo RUNN O ojo ws 47 GAS PURGE e vi e eo o wae O JL CRATER SPOT GI GAS PURGE COLD FEED SYNERGIC 7 amp 7H LINCOLN P B 3 Acceleration Selection Pressing both the Gas Purge key and then the func tion select key at the same time causes the accelera tion setting to be displayed The display will indi cate A X where X will be a number from 1 through 5 with 5 being the fastest acceleration This number can be adjusted using the arrow keys To exit this function press any other key except the arrow key gas purge or function select key Burnback Time Selection If necessary for higher wire feed speeds burnback time maybe selected to prevent the electrode from sticking in the weld puddle a the end of the weld Pressing both the Gas Purge Key then the function select key
85. so 9 STEP oc tt SPOTe e e e CS A V voLTs TRIM e ofo RUNN Sojo ws PREFLOW lt POSTFLOW gu D e e b CRATER O lt spor 3 O I e COLD FEED 47 GAS PURGE 2 STEP 1 4 STD 0 4 STEPA4 44 LOCK INSTALLATION KEYPAD AND DISPLAY DESCRIPTION Keypad Seven key membrane I type with snap tactile feel and embossed domes Long life design Spatter resistant surface Display 3 1 2 digit 7 segment LED with or polarity indica tors 56 14 2mm character height Displays arc voltage in volts wire speed in IPM or m m and all timers in seconds Indicator Lights Extra bright red LED s for viewing at almost any angle Always indicates the mode being used and which function or timer is being displayed Cold Feed key energizes the wire feeder but not the power source or solenoid valve Cold feed speed is adjustable and is displayed only while pressing Cold Feed and the last speed selected is stored in memory for the next Cold feeding Gas Purge key energizes the sole noid valve but not the wire feeder or power source Mode Select key enables operator to choose mode of operation shown by the indicator lights Pressing key causes mode lights to sequence top to bottom starting from the current indicated selection SPOTe e e e rop Light Indicates 2 step stan dard trigger mode Middle L
86. the Release Bar pops up and that the collar retainers fully engage the retaining groove on the spindle FEEDING AND BRAKE ADJUSTMENT 1 Turn the Readi Reel or spool until the free end of the electrode is accessible 2 B 6 While tightly holding the electrode cut off the bent end and straighten the first six inches Cut off the first inch If the electrode is not properly straightened it may not feed or may not go into the outgoing guide tube causing a birdnest Insert the free end through the incoming guide tube Press the cold inch key or gun trigger and push the electrode into the drive roll A WARNING T e 5 6 ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring e When inching with the gun trigger electrode and drive mechanism are hot to work and ground and could remain hot for several seconds after the gun trigger is released Inch the electrode through the gun Adjust the brake tension with the thumbscrew on the spindle hub until the reel turns freely but with little or no overrun when wire feeding is stopped Do not overtighten SYNERGIC 7 amp 7H LINCOLN P B 7 OPERATION B 7 WIRE REEL LOADING 50 AND 60 LB COILS K303 OR K376 WIRE REEL STAND ADJUSTABLE WIRE REEL BRAKE The mount for standard 50 and 60 pound electrode coils includes a two position brake assembly Generally the brake should be at
87. the gun trigger is released Turn OFF input power at welding power source before installation or changing drive roll and or guide tubes Welding power source must be connected to system ground per the National Electrical Code or any applicable local codes Only qualified personnel should perform this installation Observe all additional Safety Guidelines detailed throughout this manual Routine Maintenance Drive Rolls and Guide Tubes After feeding every coil of wire inspect the drive roll section Clean it as necessary Do not use a solvent for cleaning the idle roll because it may wash the lubricant out of the bearing The driver roll and guide tubes are stamped with the wire sizes they will feed If a wire size other than that stamped on the roll s is to be used the roll s and guide tubes must be changed The drive rolls for 035 0 9mm through 052 1 3mm cored electrode and 1 16 1 6mm through 3 32 2 4mm electrode have a double set of teeth so they can be reversed for additional life Drive rolls for 023 0 6 mm through 052 1 3 mm solid elec trodes and aluminum sizes have no teeth but use two grooves so they also can be reversed for additional life See section on Wire Feed Drive Roll and Guide Tube Kits for roll changing instructions Wire Reel Mounting 50 22 7kg and 60lb 27 2kg Coils with 1 Spindle To prolong the life of the reel shaft periodically coat it with a thin layer of gr
88. the inner position nearest to the wire reel shaft for wire feed speeds below 400 in min 10 m min It should be at the outer position for the faster wire speeds often used when feeding smaller diameter electrode To adjust the brake position remove the wire reel Pull the cotter pin that holds the brake shoe to the arm move the shoe and replace the cotter pin Do not bend the cotter pin it is held in place by a friction fit TO MOUNT A 50 OR 60 LB COIL 1 To remove the wire reel from its shaft grasp the spring loaded knob and pull out This straightens the knob so it seats into the shaft when released Remove the reel 2 Lay the reel flat on the floor Loosen the spinner nut and remove the cover plate See Figure B 2 3 Place the coil of electrode on the reel so it unwinds as the reel rotates clockwise DO NOT cut the tie wires at this time 4 Be sure the coil is placed so the spring loaded arms will not interfere with the later removal of the coil tie wires 5 When loading 0 030 to 0 045 electrode be certain the coil is placed on the reel so the spring loaded arms are at the center of the slots in the cardboard coil liner This provides the positive compression of the coil sides needed for trouble free wire feeding 6 Put the cover plate on the reel so the four arms of the cover plate straddle and are in line with the spring loaded arms of the reel 7 Tighten the cover as much as possible by hand DO NOT ha
89. the wire reel mounting stand strain relief clamp Remove the screws hold ing the clamp to the base of the wire reel mounting assembly put the input cable assembly under the clamp and reinstall the screws Work Cable Connect a work lead of sufficient size and length per the following table between the proper output terminal on the power source and the work Be sure the con nection to the work makes tight metal to metal electri cal contact Copper Work Cable Size AWG Current Up to 100 ft Length 30m 60 Duty Cycle 00 67 mm2 300 Amps 400 Amps 000 85 mm2 500 Amps 000 85 mm2 For pulse welding applications the next larger cable size is recommended OPTIONAL FEATURES INSTALLATION K178 1 Mounting Platform Synergic 7 Models on Synergic Power Sources Requires a K303 K376 K377 K378 or K445 Wire Reel Assembly This is a turntable type platform for mounting the Synergic 7 on the top of Synergic power sources Bolt the platform to the lift bail per instructions M16260 supplied with the platform K162 H Spindle for Mounting Readi Reels and 2 51 mm LD Spools 60 Ib 27 kg Capacity For use with K303 and K376 Wire Reel Stand To mount the 2 spin dle kit for Readi Reels and 10 through 60 pound spools remove the shaft for the standard 50 60 pound wire coils from the mounting framework Install the spindle per the instructions shipped with the kit When used with Readi Reels a Readi Reel Ad
90. tion gun and cable assemblies are available 250 ampere K309 350 ampere K206 and the 500 ampere K289 All gun cable lengths are 15 ft 4 5 m Both the K206 and K309 with Synergic 7 will feed electrode sizes 062 1 6 mm to 5 64 2 0 mm K289 with Synergic 7 will feed 5 64 2 0 mm electrode These guns require the use of the K184 vacuum unit for use with Synergic 7 Gun Cable Connection Wire Feeder to Gun Lay the cable out straight Insert the connector on the welding conductor cable through the large hole in the front panel of the Synergic 7 and into the brass con ductor block on the front of the gearbox Make sure it is all the way in and tighten the hand wheel Keep this connection clean and bright Connect the control cable polarized plug into the mating 5 cavity recepta cle on the front of the control section below the key pad For GMA Gun Cables Install the barbed fitting and union nut to the 5 8 18 female inert gas fitting on the front of the Synergic 7 wire drive Connect the 3 16 I D gas hose from the gun cable to the barbed fitting When the gun is to be removed this fitting can be easily detached by loosen ing the union nut SYNERGIC 7 amp 7H LINCOLN A 8 INSTALLATION Synergic 7 Water Connections for Water Cooled Guns These Synergic 7 models must have a K590 4 Water Connection Kit installed See Options Installation section 1 Using male quick connect fittings included with appropriate
91. tle control rods while the engine is running 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side Y K Connect the work cable to the workpiece as close as possible to the area being welded To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate Do not work next to welding power source Mar 95 LINCOLN SAFETY ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC
92. to the Synergic 7 is supplied and controlled from the power source The Synergic 7 automatically senses the loss of power when the power source is turned off Procedure settings including mode crater speed cold feed speed run in speed weld speed timers and acceleration are automatically saved when power is removed Arc Voltage setting is retained by the synergic power source This feature does not require batteries and when power is restored it will automati cally return all settings to the state they were in when power was removed The power source may auto matically overwrite any or all of these settings follow ing power up recall Operation Keys olo Cold Feed key energizes the wire 1 feeder but not the power source or solenoid valve This cold feed speed is digitally displayed and is COLD FEED adjustable with Arrow keys only while pressing the Cold Feed Key The last setting is held in memory for next Cold feeding Y Gas Purge key energizes the sole noid valve but not the wire feeder or GAS PURGE Power source 2 STEP y 4 aster EN M Mode Selection Mode Select key behind drop door cover enables operator to choose mode of operation shown e by the indicator lights Pressing key causes mode lights to sequence SPOTe e e e top to bottom starting from the current indicated position STD Top Light Indicates 2 Step Standard Trigger Mode Trigger closure energizes the solenoid valve
93. tric We want you Thank You io take pride in operating this Lincoln Electric Company product eee as much pride as we have in bringing this product to you Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you request replacement parts or information on this equipment always supply the information you have recorded above The code number is especially important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration Read this Operators Manua
94. ty Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION 17 Dual procedure is not functioning when using the local dual proce dure switch 18 Optional gun dual procedure switch is not functioning properly a Optional gun dual procedure switch or remote control kit may be connected Serial communication problem Faulty local dual procedure switch wiring harness or Control board a Local dual procedure switch is not in Gun position and or remote control kit s dual procedure switch is not in Gun position Faulty remote control kit Serial communication problem Faulty optional gun dual proce dure switch Faulty wiring harness or optional gun dual procedure amphenol f Faulty local dual procedure switch g Faulty Control board 44 CAUTION a When the dual procedure switch is in the Gun position then either the remote or the optional gun dual procedure switch must be used to select between procedures A and B b Make sure that parameters on power source dis play such as WFS match those on wire feeder display If not refer to Problem 14 c Disconnect harness plug from J2 on Control board Check continuity between plug pins 1 and 12 when local dual procedure switch is in position A but not when in Gun or B Now check con tinuity between plug pins 5 and 12 when local dual procedure switch is in position B
95. u rosto da fumaca Use ventilac o e exhaust o para remover fumo da zona respirat ria eti ADP5o5UtRcocuc F n 9 BAPHECTIHIAEBELTIA DM CARE MES ie B sk HE A AR e za 347148 else e 8xbiogst SUAS MAS sis PARAH 587E Assis Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien e Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten e N o opere com as tampas removidas e Desligue a corrente antes de fazer servico e N o toque as partes el tricas nuas e X7TTLA UAVCRUD PRE EFE TE DF I gt C F uv e SAUTER Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas e N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s e Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes e N o opere com os paineis abertos ou guardas removidas NKRWROPAN ERWALEEE CH B EHTEEUSXVCREU e SER RTI BB st 2 8 RE ERE EIE Ko e maol wel Me z OAL WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO it ie BIR Chinese a oe lue chal ad e TAU Gall bacs ga d Aach arin Jg n Mall oe Quad sas us Aie by pha NM uu gl Jl ale
96. ug and pin C of 14 pin plug of the input cable and between socket D of 8 socket plug and pin D of 14 pin plug of the input cable Replace cable if no continuity c Wiring harness or Control PC Check continuity between pin C of 8 pin recep board is defective tacle and pin 7 of plug P1 and between pin D of 8 pin receptacle and pin 6 of plug P1 If no continuity then harness is faulty otherwise replace Control PC board See procedure for replacing PC boards 10 Speed does not change when a Run in and weld speeds are set a Set run in and weld speeds to desired set weld current flows to the same value or run in is set tings to b Power Source may be defective b Make sure that parameters on power source or there may be a problem with display such as WFS match those on wire the Serial communications feeder display If not refer to Problem 14 Otherwise replace control PC board See procedure for replacing PC boards 11 Voltmeter does not function or fa Electrode sensing lead or connec a Check continuity from brass block on wire read properly when arc voltage is tions may be intermittent feeder to pin F of 8 pin control cable recepta present cle on wire feeder If there is no continuity repair faulty connection b Serial communication problem b Make sure that parameters on power source display such as WFS match those on wire feeder display If not refer to Problem 14 Otherwise replace Control PC b
97. wire that is larger than the rated capacity of the feeder or any other factors that would impede normal wire feeding See section on Avoiding Wire Feeder Problems SYNERGIC 7 8 7H LINCOLN P B 11 Grounding Lead Protector The frame of the Synergic 7 wire feeder is grounded to the frame of the power source by a lead in the con trol cable An overload protector prevents welding current from damaging this lead if the electrode circuit touches the wire feeder frame while the electrode is electrically hot If such a grounding lead fault occurs the wire feeder display will show GLP and the trigger circuit will be disabled To reset the circuit release the trigger make sure that the electrode is not touching the wire feeder frame and then either press any key on the keypad or close the trigger When the GLP circuit is reset the GLP display is removed and the wire feed er is returned to normal operating mode OPERATION Explanation of Prompting and Error Messages Display HI HXX EP uP EXX Er GLP SYNERGIC 7 amp 7H LINCOLN P Prompt or Error Indicates arc voltage is above 80V DC Indicates selected Run In speed will be the same as the weld speed To enter a different Run In speed simply press the increase arrow key with Run In selected Indicates wire feed overload XX indicates time remaining in seconds before unit resets automatically See sections on Routine Maintenance Periodic Maint
98. y not go into the outgoing guide tube causing a birdnest A WARNING When feeding with the gun trigger the electrode and drive mechanism are always HOT to work and ground and could remain HOT several seconds after the gun trigger is released SYNERGIC 7 amp 7H LINCOLN P B 9 OPERATION B 9 Idle Roll Pressure Setting The idle roll pressure is set at the factory backed out three turns from full pressure on 4 roll feeders This is an approximate setting For small wire sizes and aluminum wire up to 9 or 10 turns out may be required to minimize birdnesting The optimum idle roll pres sure varies with type of wire surface condition lubri cation and hardness The optimum idle roll setting can be determined as follows 1 Release the incoming idle roll pressure arm then press end of gun against a solid object that is elec trically isolated from the welder output and press the gun trigger for several seconds E If the wire birdnests jams or breaks at the drive roll the idle roll pressure is too great Back the pressure setting out 1 2 turn run new wire through gun and repeat above steps 3 If the only result is drive roll slippage disengage the gun locking nut and pull the gun cable forward about 6 150mm There should be a slight wavi ness in the exposed wire If there is no waviness the pressure is too low Increase the pressure set ting 1 4 turn reconnect the gun tighten the lo
99. yed before the weld is stopped will continue to be displayed for 5 seconds after welding to permit operator monitoring B 3 e u o e SPOT OPERATION Timer Crater Select key enables operator to choose crater speed spot or gas timers as indicated by the appro priate light Pressing key causes lights O JL CRATER to sequence left to right top to bottom starting from the current indicated posi tion Any parameter not available in the mode selected is skipped over lf a function is being displayed when the Timer Crater Select key is pressed then the light of the last parameter selected before the function was cho sen will come on and become the start ing point for the sequencing Top Left Light indicates preflow time is being displayed in seconds This is the time the shielding gas flows before the wire feed and power source are activated Top Right Light indicates postflow time is being displayed in seconds This is the time the shielding gas flows after the wire feed and power source are deactivated Middle Light indicates that crater feed Speed is being displayed Crater speed is only available when 4 step trigger with crater fill is selected See 4 step trigger mode selection section It is activated by Step 3 and deactivated by Step 4 of the 4 step sequence Bottom Light indicates spot on time is being displayed in seconds NOTE if unit is not in spot mode then thi

Lincoln Electric 7H User's Manual

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